2005 CHRYSLER VOYAGER Service Manual

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Page 465 of 2339

CHRYSLER VOYAGER 2005 Service Manual ²If multiple obstacles are detected during the
same power open or close cycle the power sliding
door may go into full manual mode.
²If severe Diagnostic Trouble Codes (DTC) are
stored in the power s

²If multiple obstacles are detected during the
same power open or close cycle the power sliding
door may go into full manual mode.
²If severe Diagnostic Trouble Codes (DTC) are
stored in the power sliding door control module the
power sliding door may go into full manual mode.
²Due to the high pressure created in the passen-
ger compartment with the blower motor on high, the
power sliding door may not complete a power close
cycle unless a window is cracked, allowing the pres-
sure to escape. This situation will only be experi-
enced on some vehicles, or vehicles with brand new
side door weather seals installed.
²The fuel tank filler door must be in the closed
position. Due to the sliding door interference with
the open fuel tank filler door, a mechanical linkage
prevents the side door from opening and striking the
fuel door. Refer to the Body section of this manual for
detailed information on the fuel door lockout feature.
POWER SLIDING DOOR SYSTEM WARNINGS
WARNING: ALWAYS DISCONNECT THE NEGATIVE
BATTERY CABLE BEFORE ATTEMPTING ANY
POWER SLIDING DOOR SYSTEM SERVICE.
WARNING: EXTREME CARE MUST BE TAKEN TO
PREVENT OBJECTS FROM ENTERING THE DOORS
PATH ONCE THE DOOR REACHES THE CINCH
MOTOR CONTACT (APPROXIMATELY 1 INCH
BEFORE FULLY CLOSED). NEVER PLACE
OBJECTS IN THE POWER SLIDING DOOR WHEN
CINCHING CLOSED. THE OBSTACLE DETECTION
FUNCTION IS INOPERATIVE DURING THE CINCH
PHASE AND DAMAGE TO THE VEHICLE, POWER
SLIDING DOOR SYSTEM OR COMPONENTS
AND/OR PERSONAL INJURY MAY OCCUR.
WARNING: NEVER ATTEMPT TO ENTER OR EXIT
THE VEHICLE WHILE THE POWER SLIDING DOOR
IS IN MOTION. YOU COULD DAMAGE THE POWER
SLIDING DOOR SYSTEM OR COMPONENTS
AND/OR CAUSE PERSONAL INJURY.WARNING: NEVER ATTEMPT TO DRIVE AWAY WITH
THE POWER SLIDING DOOR IN MOTION. YOU
COULD DAMAGE THE POWER SLIDING DOOR SYS-
TEM OR COMPONENTS AND/OR CAUSE PER-
SONAL INJURY.
DIAGNOSIS AND TESTING
POWER SLIDING DOOR SYSTEM
The power sliding door system contains many com-
ponents and modules. In order to obtain conclusive
testing, the Programmable Communications Interface
(PCI) data bus network and all of the electronic mod-
ules that provide inputs to, or receive outputs from
the power sliding door system must be checked.
The power sliding door system was designed to be
diagnosed with an appropriate diagnostic scan tool,
such as the DRB IIIt. The most reliable, efficient,
and accurate means to diagnose the power sliding
door system requires the use of a DRB IIItscan tool
and the proper Body Diagnostic Procedures manual.
The DRB IIItcan be used to observe various switch
statuses throughout the power sliding door system to
help the technician diagnose a defective switch or
component. The DRB IIItcan also be used to actuate
various components throughout the power sliding
door system to help the technician diagnose a defec-
tive component.
Before any testing of the power sliding door system
is attempted, the battery should be fully charged, all
built-in power sliding door system inhibitors read
and understood (Refer to 8 - ELECTRICAL/POWER
DOORS - OPERATION) and all wire harness and
ground connections inspected around the affected
areas on the vehicle.
The following are quick reference diagnostic tables
to help when diagnosing and testing the power slid-
ing door system.
8N - 42 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)

Page 466 of 2339

CHRYSLER VOYAGER 2005 Service Manual POWER SLIDING DOOR SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Door opens unexpectedly Inoperative sliding door control module
or Body Control Module (BCM)Disconnect then reconnect battery n

Page 467 of 2339

CHRYSLER VOYAGER 2005 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
Check for foreign matter preventing the
operation of handle assembly
Replace the handle if necessary
Inoperative latch assembly Check cable connections
Check for f

Page 468 of 2339

CHRYSLER VOYAGER 2005 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
Wiring problems (system or vehicle) Troubleshoot using the appropriate wiring
information
Power loss during power
door operationWiring problems (system or vehicle)

CONDITION POSSIBLE CAUSES CORRECTION
Wiring problems (system or vehicle) Troubleshoot using the appropriate wiring
information
Power loss during power
door operationWiring problems (system or vehicle) Troubleshoot using the appropriate wiring
information
Low battery voltage Charge battery
Inoperative sliding door control module
or BCMDisconnect then reconnect battery negative
cable to reset module. Cycle door, if no
function exists check for loose wire
connections, see Body Diagnostic Manual for
detailed procedures
Inoperative drive assembly Remove lower drive unit and check for no
drive condition
No latching in primary and/or
secondary positionsInoperative inside/outside handle
assemblyGo to that9POSSIBLE CAUSE9and review
9CORRECTIONS9
Inoperative latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Binding or sticking of components Establish location of binding and replace
necessary components
Inoperative sliding door control module
or BCMDisconnect then reconnect battery negative
cable to reset module. Cycle door, if no
function exists check for loose wire
connections, see Body Diagnostic Manual for
detailed procedures
Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter. (Refer to 8 - ELECTRICAL/
POWER DOORS - STANDARD
PROCEDURE) for door adjustment
procedure and specifications in the Body
section of the service manual for
specifications
Inoperative drive assembly Remove lower drive unit and check for no
drive condition
Inoperative striker Striker misaligned or loose
Striker damaged
Replace striker if necessary
Latch will not fully release
from primary positionInoperative latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
RSPOWER SLIDING DOOR SYSTEM8N-45
POWER SLIDING DOOR SYSTEM (Continued)

Page 469 of 2339

CHRYSLER VOYAGER 2005 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
Inoperative fuel filler door lockout
mechanismCheck operation of fuel filler door lockout
mechanism.
Inoperative sliding door control module
or BCMDisconnect then

Page 470 of 2339

CHRYSLER VOYAGER 2005 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
Full open switch inoperative, replace hold
open latch assembly
Replace motor assembly. if necessary
Door does not stay open Inoperative hold open latch assembly Ch

CONDITION POSSIBLE CAUSES CORRECTION
Full open switch inoperative, replace hold
open latch assembly
Replace motor assembly. if necessary
Door does not stay open Inoperative hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary
Inoperative hold open latch striker Replace hold open latch striker, if necessary
High inside/outside opening
effortInoperative latch assembly Check wire connections and for blown fuse
Check cable connections
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Inoperative inside/outside handle
assemblyGo to that9POSSIBLE CAUSE9and review
9CORRECTIONS9
Binding or sticking of components Establish location of binding and replace
necessary components
Door continues to cinch
closed during power modeInoperative latch assembly Check wire connections and for blown fuse
Check for foreign matter preventing the
operation of latch assembly
Troubleshoot using body diagnostic manual
Replace latch assembly, if necessary
Inoperative sliding door control module
or BCMDisconnect then reconnect battery negative
cable to reset module. Cycle door, if no
function exists check for loose wire
connections, see Body Diagnostic Manual for
detailed procedures
Wiring problems (system or vehicle) Troubleshoot using the appropriate wiring
information
Door continues to open
during power mode (runaway
motor)Inoperative sliding door control module
or BCMDisconnect then reconnect battery negative
cable to reset module. Cycle door, if no
function exists check for loose wire
connections, see Body Diagnostic Manual for
detailed procedures
Inoperative hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary
Inoperative drive assembly Remove lower drive unit and check for no
drive condition
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Door opens very slowly Inoperative door motor assembly Check wire/cable connections
Replace motor assembly, if necessary
RSPOWER SLIDING DOOR SYSTEM8N-47
POWER SLIDING DOOR SYSTEM (Continued)

Page 471 of 2339

CHRYSLER VOYAGER 2005 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
Binding or sticking of components Establish location of binding and replace
necessary components
Squeaks, Noises and rattles Foreign material in door compartment R

CONDITION POSSIBLE CAUSES CORRECTION
Binding or sticking of components Establish location of binding and replace
necessary components
Squeaks, Noises and rattles Foreign material in door compartment Remove foreign material
Loose components Check and tighten loose components
Missing stabilizers, bumpers or
anti-rattle componentsCheck to ensure components are present.
Replace as necessary
Misadjusted stabilizers, bumpers or
anti-rattle componentsAdjust components as necessary
Poor door track lubrication Lubricate the front portions of the side door
tracks with9Door EaseT9or equivalent
STANDARD PROCEDURE
POWER SLIDING DOOR LEARN CYCLE
Any time a power sliding door component is removed,
replaced, door adjustment is performed or diagnostic
trouble codes are addressed and erased, a learn cycle
mustbe performed. This learn cycle enables the power
sliding door control module to learn or relearn its critical
information (travel limits, resistance to door travel, etc.)
which allows it to perform properly and safely. To per-
form a power sliding door learn cycle do the following:
(1)Obtain a DRB IIIt, or equivalent scan tool.
Connect the scan tool to the vehicle and check for
any power sliding door system stored diagnostic trou-
ble codes, erase any stored codes. Operate the system
and check to see if any trouble codes return. If any
diagnostic trouble codes return, diagnose, correct and
erase the codes before performing the learn cycle. If a
DRB IIIt, or equivalent scan tool is not available, the
learn cycle can be performed by opening and closing
the power sliding door using any of the normal open/
close command switches. Be certain to cycle the
power sliding door through a complete openand
close cycle or the procedure will not be complete.
(2) Using the scan tool, Go into Test Routine Menu
and select a power open command.
(3) Select a power close command.
(4) The power side door learn cycle is complete.
NOTE: If the power sliding door will not complete a
full cycle, a problem exists with the power sliding door
system. (Refer to 8 - ELECTRICAL/POWER DOORS -
DIAGNOSIS AND TESTING) for additional information.
PUSH-PIN GROMMET REPLACEMENT
Push-pin grommets are used to hold and isolate
the power sliding door motor to and from the door
inner panel. This secures the door motor assembly to
the inner panel and keeps the audible motor vibra-
tions to a minimum. If a push-pin grommet showssigns of wear, it must be replaced. Follow the proce-
dure below if replacement is necessary.
(1) Remove the door motor from the door inner
panel. (Refer to 8 - ELECTRICAL/POWER DOORS/
MOTOR - REMOVAL).
(2) Using a trim panel tool (special tool #C-4755)
or equivalent, remove the push-pin grommets from
the inner panel by pulling them straight out (Fig. 2).
(3) Install the replacement push-pin grommets in
the inner panel and install the door motor(Refer to 8
- ELECTRICAL/POWER DOORS/MOTOR - INSTAL-
LATION).
Fig. 2 SIDE DOOR MOTOR PUSH-PIN GROMMETS
1 - PUSH-PIN GROMMETS
2 - SIDE DOOR INNER PANEL
8N - 48 POWER SLIDING DOOR SYSTEMRS
POWER SLIDING DOOR SYSTEM (Continued)

Page 472 of 2339

CHRYSLER VOYAGER 2005 Service Manual POWER SLIDING DOOR ADJUSTMENT
In order for the power sliding door system to func-
tion properly the door must move freely and
smoothly. The power sliding door system can accom-
modate for some minor c

POWER SLIDING DOOR ADJUSTMENT
In order for the power sliding door system to func-
tion properly the door must move freely and
smoothly. The power sliding door system can accom-
modate for some minor changes in the effort required
to move the door. However, in extreme conditions the
door may need to be mechanically adjusted for proper
fit. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS).
If a problem exists with the power sliding door and
it is suspected to be extreme effort, check for proper
door alignment and adjustment first, then check the
door tracks and drive unit for free manual operation.
(Refer to 23 - BODY/DOORS - SLIDING/SLIDING
DOOR - ADJUSTMENTS) for detailed instructions.
LATCH
DESCRIPTION
One power latch is used for each power sliding door.
The latch is located on the trailing edge of the sliding
door assembly (Fig. 3). This power latch assembly is com-
prised of many different components which have the abil-
ity to perform the power cinch, release, lock, unlock and
safety related operations. These components are the door
latch, lock/unlock actuator, cinch/release actuator and
child lockout, pawl, ratchet and handle switches. The
pawl and ratchet switches are used to indicate the pri-
mary and secondary latched positions. The cinch latch
also provides a connection point for the interior handle,exterior handle and hold open latch cables. If any of the
components of the latch assembly are inoperative the
complete power latch assembly must be replaced.
OPERATION
The power latch performs the same operation as a full
manual door latch as well as power cinch, release, lock
and unlock operations. The power latch mounted actua-
tor cinches the door closed and latches it in its primary
latched position. During a power close cycle, the power
cinch actuator will not operate until the power sliding
door has reached its secondary latch position (deter-
mined by pawl and ratchet switches). During a power
open cycle, the power release actuator will stop once the
sliding door has moved from the primary latch position.
The power latch uses inputs from the lock/unlock
actuator, power sliding door control module and child
lockout, pawl, ratchet and handle switches to provide
safe power cinch and release operations. (Refer to 8 -
ELECTRICAL/POWER DOORS - OPERATION) for
additional information.
REMOVAL
(1)Disconnect and isolate the battery negative cable.
(2) Remove the appropriate side door trim panel,
(Refer to 23 - BODY/DOORS - SLIDING/TRIM
PANEL - REMOVAL).
(3) Remove the weather shield if necessary.
(4) Open the side door all the way and remove the
door latch retaining bolts (Fig. 4).
Fig. 3 REMOVING/INSTALLING POWER LATCH IN
SLIDING DOOR
1 - POWER LATCH ASSEMBLY
Fig. 4 REMOVING LATCH RETAINING BOLTS
1 - LATCH RETAINING BOLTS
2 - SIDE DOOR
RSPOWER SLIDING DOOR SYSTEM8N-49
POWER SLIDING DOOR SYSTEM (Continued)

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