2005 CHRYSLER VOYAGER Service Manual

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Page 345 of 2339

Page 346 of 2339

CHRYSLER VOYAGER 2005 Service Manual HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS........................... 1
HEATED MIRRORS......................... 6HEATED SEAT SYSTEM..................... 7
HEATED GLASS
TABLE OF CONTENTS
p

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CHRYSLER VOYAGER 2005 Service Manual OPERATION
When the rear window defogger button is
depressed to the On position, current is directed to
the rear defogger grid lines and the heated power
mirrors (if equipped). The heated grid lines he

OPERATION
When the rear window defogger button is
depressed to the On position, current is directed to
the rear defogger grid lines and the heated power
mirrors (if equipped). The heated grid lines heat the
glass to help clear the rear window and side mirror
surfaces of fog or frost.
The electric backlight (EBL) system is controlled
by a momentary switch located in the A/C-heater
control on the instrument panel. A yellow indicator in
the switch will illuminate to indicate when the sys-
tem is turned on. The integrated power module (IPM)
contains the EBL system control circuitry.
NOTE: The rear window defogger turns off automat-
ically after approximately 10 minutes of initial oper-
ation. Each following activation cycle of the
defogger system will last approximately five min-
utes.
The EBL system will be automatically turned off
after a programmed time interval of about ten min-
utes. After the initial time interval has expired, if the
defogger switch is turned on again during the same
ignition cycle, the defogger system will automatically
turn off after about five minutes.
The EBL system will automatically shut off if the
ignition switch is turned to the Off position, or it can
be turned off manually by depressing the defogger
switch a second time.
DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM
NOTE: Illumination of the defogger switch indicator
lamp means that there is electrical current available
at the output of the rear window defogger logic cir-
cuitry, but does not confirm that the electrical cur-
rent is reaching the rear glass heating grid lines.
NOTE: For circuit descriptions and diagrams of the
rear window defogger system, refer to 8W - WIRING
DIAGRAM INFORMATION.
Operation of the electrical backlight (EBL) system
can be confirmed by the following:(1) Turn the ignition switch to the On position. Set
the defogger switch in the On position. The rear win-
dow defogger operation can be checked by feeling the
rear window glass. A distinct difference in tempera-
ture between the grid lines and the adjacent clear
glass can be detected within three to four minutes of
operation.
(2) If a temperature difference is not detected, use
a 12-volt DC voltmeter and contact the rear glass
heating grid terminal B with the negative lead, and
terminal A with the positive lead (Fig. 2). The volt-
meter should read battery voltage. If the voltmeter
does not read battery voltage, check the following:
²Confirm that the ignition switch is in the On
position.
²Make sure that the rear glass heating grid feed
wire and ground wire are connected to the terminals.
Confirm that the ground wire has continuity to
ground.
²Check that fuse 13 (40 amp) in the integrated
power module (IPM) is OK. The fuse must be tight in
it's receptacle and all electrical connections must be
secure.
(3) When the above steps have been completed and
the rear glass heating grid is still inoperative, one or
more of the following is faulty. It may be necessary to
connect a DRBIIItscan tool to perform further diag-
nostics. Refer to Body Diagnostic Procedures.
²Rear window defogger switch in the A/C-heater
control.
²J1850 bus communication between the A/C-
heater control and the front control module (FCM).
²Rear window defogger (EBL) relay in the IPM.
²Rear window defogger (EBL) relay control circu-
ity in the IPM.
²Check for a loose wire connector or a wire
pushed out of a connector.
²Rear window grid lines (all grid lines would
have to be broken, or the power feed or ground wire
not connected, for the entire heating grid to be inop-
erative).
(4) If the system operation has been verified but
defogger switch LED indicator does not illuminate,
replace the A/C-heater control.
8G - 2 HEATED GLASSRS
HEATED GLASS (Continued)

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CHRYSLER VOYAGER 2005 Service Manual (5) If broken defogger grid lines are suspected, use
a 12-volt DC voltmeter and contact terminal B with
the negative lead and each rear glass heating grid
line at its mid-point with the positive lead

(5) If broken defogger grid lines are suspected, use
a 12-volt DC voltmeter and contact terminal B with
the negative lead and each rear glass heating grid
line at it's mid-point with the positive lead. The volt-
meter should read approximately 6 volts at each grid
line mid-point C. If the voltmeter does not read
approximately 6 volts, repair the open grid line(s)
(Refer to 8 - ELECTRICAL/HEATED GLASS/REAR
WINDOW DEFOGGER GRID - STANDARD PROCE-
DURE).
REAR WINDOW DEFOGGER
RELAY
DESCRIPTION
The rear window defogger (EBL) relay (Fig. 3) is a
International Standards Organization (ISO)-type
relay. Relays conforming to the ISO specifications
have common physical dimensions, current capaci-
ties, terminal patterns, and terminal functions. The
rear window defogger relay is a electromechanical
device that switches battery current through a fuse
in the integrated power module (IPM) to the rear
window defogger grid and switches battery current
through a positive thermal coefficient (PTC) in the
IPM to the outside mirror heating grids. The relay isenergized when the relay coil is provided a ground
path by the rear window defogger relay control in the
front control module (FCM).
The rear window defogger (EBL) relay is located in
the IPM in the engine compartment. See the fuse
and relay layout map on the inner surface of the
cover of the IPM for rear window defogger relay iden-
tification and location.
The rear window defogger (EBL) relay cannot be
adjusted or repaired and, if damaged or faulty, it
must be replaced.
OPERATION
The ISO-standard rear window defogger (EBL)
relay consists of an electromagnetic coil, a resistor or
diode, and three (two fixed and one movable) electri-
cal contacts. The movable (common feed) relay con-
tact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor is connected in
parallel with the electromagnetic coil in the relay,
and helps to dissipate voltage spikes that are pro-
duced when the coil is de-energized.
Refer to the appropriate wiring information for
diagnosis and testing of the EBL relay and for com-
plete EBL system wiring diagrams.
Fig. 2 Grid Line Test
1 - VOLTMETER
2 - VOLTAGE FEED (A)
3 - FEED WIRE
4 - MID-POINT (C)
5 - HEATED WINDOW GRID
6 - GROUND WIRE
7 - GROUND (B)Fig. 3 Rear Window Defogger (EBL) Relay
RSHEATED GLASS8G-3
HEATED GLASS (Continued)

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CHRYSLER VOYAGER 2005 Service Manual REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the integrated power
module (IPM) (Fig. 4).
NOTE: Refer to the fuse and relay layout map on
the inner surface o

REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the integrated power
module (IPM) (Fig. 4).
NOTE: Refer to the fuse and relay layout map on
the inner surface of the cover of the IPM for rear
window defogger (EBL) relay identification and
location.
(3) Remove the EBL relay from the IPM.
INSTALLATION
NOTE: Refer to the fuse and relay map on the inner
surface of the cover of the integrated power module
(IPM) for rear window defogger (EBL) relay identifi-
cation and location.
(1) Position the EBL relay into the proper recepta-
cle in the IPM.
(2) Align the EBL relay terminals with the termi-
nal cavities in the IPM receptacle.
(3) Push down firmly on the EBL relay until the
terminals are fully seated in the terminal cavities.
(4) Install the cover onto the IPM.
(5) Reconnect the negative battery cable.
REAR WINDOW DEFOGGER
SWITCH
DESCRIPTION
The switch for the EBL system is integrated into
the A/C-heater control located in the center of the
instrument panel (Fig. 5).
When the rear window defogger switch is turned to
the ON position, current is directed to the rear defog-
ger grid lines and the heated power mirrors (if
equipped). The heated grid lines heat the glass to
help clear the surface of fog or frost.
OPERATION
Depressing the rear window defogger switch ener-
gizes the A/C-heater control module which then
requests the front control module (FCM) to activate
the rear window defogger (EBL) relay via the com-
munication bus. The EBL relay controls the current
to flow to the grids of the rear window defogger and
the heated power side view mirrors. The EBL relay
will be on for approximately 10 minutes or until the
control switch or ignition is turned off. An amber
indicator lamp in the defogger switch illuminates to
indicate when the EBL system is On.
The rear window defogger switch and indicator
lamp cannot be repaired and, if faulty or damaged,
the entire A/C-heater control must be replaced.
Fig. 4 Rear Window Defogger (EBL) Relay
1 - INTEGRATED POWER MODULE (IPM)
2 - REAR WINDOW DEFOGGER (EBL) RELAY
3 - FRONT CONTROL MODULE (FCM)
Fig. 5 A/C-Heater Control - Typical
1 - TRIM BEZEL
2 - INFRARED TEMPERATURE SENSOR
3 - A/C REQUEST SWITCH
4 - EBL/HEATED MIRROR SWITCH
5 - FRONT WINDOW DEFROSTER SELECTOR
8G - 4 HEATED GLASSRS
REAR WINDOW DEFOGGER RELAY (Continued)

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CHRYSLER VOYAGER 2005 Service Manual REAR WINDOW DEFOGGER
GRID
STANDARD PROCEDURE
GRID REPAIR PROCEDURE
WARNING: Materials contained in the Repair Kit
(Part Number 04549275) may cause skin or eye irri-
tation. The kit contains epoxy resi

REAR WINDOW DEFOGGER
GRID
STANDARD PROCEDURE
GRID REPAIR PROCEDURE
WARNING: Materials contained in the Repair Kit
(Part Number 04549275) may cause skin or eye irri-
tation. The kit contains epoxy resin and amine type
hardener, which are harmful if swallowed. Avoid
contact with the skin and eyes. For skin contact,
wash the affected areas with soap and water. For
contact with the eyes, flush with plenty of water. Do
not take internally. If taken internally, induce vomit-
ing and call a physician immediately. Use with ade-
quate ventilation. Do not use near fire or flame.
Contains flammable solvents. Keep out of the reach
of children. Failure to follow the warnings could
result in possible personal injury or death.
Repair of the rear glass heating grid lines, bus
bars or terminals can be accomplished using the
MopartRear Window Defogger Repair Kit (Part
Number 04549275) or equivalent.
(1) Mask the repair area with masking tape so
that the conductive epoxy can be applied neatly (Fig.
6). Extend the epoxy application onto the grid line or
the bus bar on each side of the break.
(2) Follow the instructions in the repair kit for
preparing the damaged area.
(3) Remove the package separator clamp and mix
the two conductive epoxy components thoroughly
within the packaging. Fold the package in half and
cut the center corner to dispense the epoxy.
(4) For grid line repairs, mask the area to be
repaired with masking tape or use a template.
(5) Apply the epoxy through the slit in the mask-
ing tape or template. Overlap both ends of the break
by at least 19 millimeters (0.75 inch).
(6) For a terminal replacement, mask the adjacent
areas so the epoxy can be extended onto the adjacent
grid line as well as the bus bar. Apply a thin layer of
epoxy to the area where the terminal was fastened
and onto the adjacent grid line.(7) Apply a thin layer of conductive epoxy to the
terminal and place it in the proper location on the
bus bar. To prevent the terminal from moving while
the epoxy is curing, it must be wedged or clamped.
(8) Carefully remove the masking tape or tem-
plate.
CAUTION: Do not allow the glass surface to exceed
204É C (400É F) when using a heat gun, or the glass
may fracture.
(9) Allow the epoxy to cure 24 hours at room tem-
perature, or carefully use a heat gun for fifteen min-
utes. When using a heat gun, hold it approximately
25.4 centimeters (10 inches) from the repair and do
not allow the glass surface to exceed 204É C (400É F).
NOTE: Do not attach the wire harness connectors
to the terminals until the curing process is com-
plete.
(10) After the conductive epoxy is properly cured,
remove the wedge or clamp from the terminal.
(11) Connect the wire harness leads to the grid
terminals and verify EBL operation.
Fig. 6 Grid Line Repair
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
RSHEATED GLASS8G-5

Page 351 of 2339

CHRYSLER VOYAGER 2005 Service Manual HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION..........................6OPERATION............................6
HEATED MIRRORS
DESCRIPTION
The optional heated mirror system is c

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CHRYSLER VOYAGER 2005 Service Manual HEATED SEAT SYSTEM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM
DESCRIPTION..........................7
OPERATION............................8
DIAGNOSIS AND TESTING
HEATED SEAT SYSTEM................

HEATED SEAT SYSTEM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM
DESCRIPTION..........................7
OPERATION............................8
DIAGNOSIS AND TESTING
HEATED SEAT SYSTEM.................8
HEATED SEAT SWITCH
DESCRIPTION..........................8
OPERATION............................9
DIAGNOSIS AND TESTING
DRIVER HEATED SEAT SWITCH..........9
REMOVAL.............................10
INSTALLATION.........................10HEATED SEAT ELEMENTS
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING
HEATED SEAT ELEMENTS..............11
REMOVAL.............................12
INSTALLATION.........................12
HEATED SEAT SENSOR
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING
HEATED SEAT SENSOR................13
HEATED SEAT SYSTEM
DESCRIPTION
Vehicles with the heated seat option can be visu-
ally identified by the two separate heated seat
switches located in the instrument panel center
stack, just above the radio (Fig. 1). The heated seat
system allows the front seat driver and passenger to
select from two different levels of supplemental elec-
trical seat heating (HI/LO), or no seat heating to suit
their individual comfort requirements. The heated
seat system for this vehicle includes the following
major components:
²Heated Seat Elements- Four heated seat ele-
ments are used per vehicle, two for each front seat.
One heated seat element is integral to each front
seat trim cover, one in the seat back and one in the
seat bottom (cushion). Service replacement heating
elements are available, (Refer to 8 - ELECTRICAL/
HEATED SEATS/HEATED SEAT ELEMENT -
DESCRIPTION) for additional information.
²Heated Seat Modules- Two heated seat mod-
ules are used per vehicle. One module is mounted to
each of the seat cushion pans, located under the for-
ward edge of each front seat. (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/
MEMORY HEATED SEAT/MIRROR MODULE -
DESCRIPTION) for additional information.
²Heated Seat Sensors- Two heated seat sen-
sors are used per vehicle, one for each front seat. The
heated seat sensors are integral to each of the heated
seat bottoms (cushions).
²Heated Seat Switch- Two heated seat
switches are used per vehicle, one for the driver and
one for the passenger side front seats. The switches
are mounted in the instrument panel center stack.
(Refer to 8 - ELECTRICAL/HEATED SEATS/
DRIVER HEATED SEAT SWITCH - DESCRIPTION)
for additional information.
Fig. 1 HEATED SEAT SWITCH LOCATIONS
1 - HEATED SEAT SWITCHES
RSHEATED SEAT SYSTEM8G-7

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