2005 CHRYSLER VOYAGER Rear system

STANDARD PROCEDURE
LIFTGATE ADJUSTMENT
In order for the power liftgate system to function
properly the liftgate must move freely and smoothly.
The power liftgate system can accommodate for some
minor changes in the effort required to move the lift-
gate. However, in extreme conditions the liftgate may
need to be mechanically adjusted for proper fit and
finish. (Refer to 23 - BODY/DECKLID/HATCH/LIFT-
GATE/TAILGATE/LIFTGATE - INSTALLATION) for
detailed instructions.
If a problem exists with the power liftgate and it is
suspected to be extreme effort, check the liftgate prop
rods and hinges for free movement.
NOTE: Routine application of Mopar MP-50Tor
equivalent on the chrome prop rod shafts and lift-
gate latch and hinges will help keep the liftgate in
good working order.
POWER LIFTGATE LEARN CYCLE
Any time a power liftgate component is removed,
replaced or a liftgate adjustment is performed a learn
cycle must be performed. This learn cycle enables the
power liftgate control module to learn or relearn
information (travel limits, resistance to door travel,
etc.) which allows it to perform properly and safely.
Perform the following to complete a power liftgate
learn cycle:
(1) Obtain a DRBIIIt, or equivalent scan tool.
(2) Connect the scan tool to the vehicle and check
for any power liftgate system stored Diagnostic Trou-
ble Codes (DTCs), correct and erase any stored
DTCs.
(3) Using the scan tool, Go into Test Routine Menu
and select the power open command.
(4) Select the power close command.
(5) The liftgate learn cycle is complete.
If a DRBIIItor equivalent scan tool is not avail-
able, the learn cycle can be performed by actuating
the liftgate using any of the normal command
switches. Be certain to cycle the liftgate through a
complete open and close cycle before returning the
vehicle to service.
NOTE: If the power liftgate will not complete a full
cycle a problem exists with the power liftgate sys-
tem. (Refer to 8 - ELECTRICAL/POWER DOORS -
DIAGNOSIS AND TESTING).
CHIME/THERMISTOR
DESCRIPTION
The chime/thermistor assembly is a small capacitor
shaped electrical component mounted to the rear
license plate lamp housing assembly (Fig. 2) , located
just above the license plate. The chime portion of the
assembly controls the audible chime sound heard at
the rear of the vehicle when the power liftgate is in
motion. The thermistor portion of the assembly is a
temperature sensor, used by the power liftgate con-
trol module. The chime/thermistor assembly is a ser-
viceable component.
OPERATION
The chime/thermistor assembly performs two dif-
ferent functions for the power liftgate system. First,
the chime portion provides an audible chime sound
which is controlled by the power liftgate control mod-
ule. The chime/thermistor assembly is hardwired to
the power liftgate control module. Second the ther-
mistor provides a outside temperature reading by
way of a resistance reading supplied to the power
liftgate control module. As temperature increases the
resistance reading increases, as temperature
decreases the resistance reading decreases.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
Fig. 2 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
8N - 8 POWER LIFTGATE SYSTEMRS
POWER LIFTGATE SYSTEM (Continued)

(2) Remove the rear light bar assembly from the
vehicle. (Refer to 8 - ELECTRICAL/POWER DOORS/
SWITCH - REMOVAL) for the procedure.
(3) Grasp the light bar at its sides next to ther-
mistor/chime assembly and gently pull the two sides
of the light bar apart until the thermistor/chime
assembly can be removed.
INSTALLATION
(1) Gently pull the two sides of the light bar apart
until the thermistor/chime assembly can be installed.
(2) Install the rear light bar assembly on the vehi-
cle. (Refer to 8 - ELECTRICAL/POWER DOORS/
SWITCH - INSTALLATION) for the procedure.
(3) Connect the battery negative cable.
ENGAGE ACTUATOR
DESCRIPTION
The 12 volt engage actuator (Fig. 3) provides the
engagement and disengagement of the liftgate gear
motor to the lift gear by way of an over center link,
activated by a lever.
The engage actuator is a serviceable component
and cannot be repaired, if found to be inoperative it
must be replaced.
OPERATION
The engage actuators normal position is disen-
gaged. When a power liftgate open or close command
is generated from any of the command switches, the
power liftgate control module signals the engage
actuator to move its lever to the engaged position.
This engages the gear motor to the lift gear, so when
the motor turns the lift gate moves upward or down-
wards depending on its current position.
During a manual liftgate open or close cycle the
engage actuator is disengaged, allowing unrestricted
liftgate movement.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the left rear D-pillar trim from the
vehicle, (Refer to 23 - BODY/INTERIOR/LEFT
D-PILLAR TRIM PANEL - REMOVAL).
(3) Manually engage the actuator link rod, this
must be done to access one of the engage actuator
retaining screws.
(4) Remove the two engage actuator retaining
screws (Fig. 4).
(5) Disconnect the engage actuator electrical con-
nector and remove the engage actuator from the
vehicle.
Fig. 3 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 4 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
RSPOWER LIFTGATE SYSTEM8N-9
CHIME/THERMISTOR (Continued)

INSTALLATION
(1) Position the engage actuator in the vehicle and
connect the engage actuator electrical connector.
(2) Install the two engage actuator retaining
screws.
(3) Manually disengage the actuator.
(4) Install the left rear D-pillar trim on the vehi-
cle, (Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Using an appropriate scan tool, check and
erase any power liftgate control module diagnostic
trouble codes.
(7) Verify power liftgate system and engage actua-
tor operation. Cycle the power liftgate through one
complete open and close cycle.
EXTERIOR HANDLE SWITCH
DESCRIPTION
The exterior handle switch is an electronic release
switch mounted to the rear license plate lamp hous-
ing assembly, located just above the license plate.
This switch controls the power liftgate release func-
tion and is also capable of reversing the power lift-
gate when it is in motion. A full power open cycle
cannot be performed using this switch, only one of
the power open command switches (key fob and over-
head console mounted) can be used to perform a full
power open cycle. The exterior handle switch is a ser-
viceable component.
OPERATION
When the exterior handle switch is depressed, with
the liftgate in the closed position, a message is sent
to the Body Control Module (BCM). The BCM then
sends a signal to the power liftgate control module
via the Programmable Communication Interface
(PCI) data bus circuit. The power liftgate control
module then sends a signal to the power latch
mounted actuator, which moves the liftgate from the
primary closed and latched position to the open and
movable position. If the liftgate is not pulled open
once the latch releases within a few seconds, the
latch will cinch closed again.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Open the liftgate and remove the liftgate trim
panel, (Refer to 23 - BODY/DECKLID/HATCH/LIFT-
GATE/TAILGATE/TRIM PANEL - REMOVAL).
(3) Remove the rear lamp bar assembly from the
vehicle.(4) Locate the two wires going to the exterior han-
dle switch. Cut the tie strap and trace the wires to
the large electrical connector and back the wires out
of the large connector and through the grommet.
Take care to mark the location of the wire ter-
minals in relation to the large connector so
that they are positioned in the appropriate cav-
ities upon switch installation.
(5) Depress the two exterior handle switch retain-
ing tabs and roll the switch out of the light bar
assembly (Fig. 5).
INSTALLATION
(1) Install the handle switch in the light bar
assembly (Fig. 6).
(2) Locate the two wires going to the exterior han-
dle switch. Install the wires through the grommet
and in the large connector. Secure with a tie strap.
NOTE: Be certain wires are reinstalled in the correct
wire cavities. Failure to do so could result in dam-
age to the handle switch. Refer to the appropriate
wiring information for complete circuit schematic or
connector pin-out information.
(3) Install the rear light bar.
(4) Install the liftgate trim panel, (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
Fig. 5 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
8N - 10 POWER LIFTGATE SYSTEMRS
ENGAGE ACTUATOR (Continued)

(7) Verify power liftgate system and handle switch
operation. Cycle the power liftgate through one com-
plete open and close cycle, this will allow the power
liftgate control module to relearn its cycle with the
new components.
FULL OPEN SWITCH
DESCRIPTION
The full open switch is located on the gear motor
housing (Fig. 7) and is used to signal the power lift-
gate control module when the power liftgate is in the
full open position. Two wires are used from the full
open switch contacts to the gear motor assemblies
main electrical connector. The full open switch is a
serviceable component.
OPERATION
When the power liftgate reaches the full open posi-
tion, the gear motor housing mounted full open
switch electrical contacts close. This sends a ground
signal to the power liftgate control module, telling
the module that the liftgate has reached the full open
position.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lift gear and link rod assembly
from the vehicle(Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - REMOVAL).(3) Cut the two wires leading to the full open
switch or back the wires out of the electrical connec-
tor.
(4) Remove the full open switch retaining screw
and remove the full open switch from the gear motor
housing assembly.
INSTALLATION
(1) Perform a wiring repair on the full open switch
wires following the approved procedure in the Wiring
section of the service manual. Or install new termi-
nals on the wire ends and reinstall in the main lift-
gate motor electrical connector.
(2) Position and install the full open switch retain-
ing screw.
(3) Install the power liftgate lift gear and link rod
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - INSTALLATION)
(4) Connect the battery negative cable.
(5) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(6) Verify power liftgate system and full open
switch operation. Cycle the power liftgate through
one complete open and close cycle, this will allow the
power liftgate control module to relearn its cycle with
the new components.
Fig. 6 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
Fig. 7 FULL OPEN SWITCH LOCATION
1 - FULL OPEN SWITCH
2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
RSPOWER LIFTGATE SYSTEM8N-11
EXTERIOR HANDLE SWITCH (Continued)

LIFTGATE MOTOR
DESCRIPTION
The gear motor assembly (Fig. 14) consists of a DC
motor, hall effect sensor, engage actuator, full open
switch, lift gear, aluminum housing, drive gears and
wire harness. The gears and motor portion of the
assembly provides the power and torque required to
open or close the liftgate. The hall effect sensor is used
to provide the liftgate control module with a speed read-
ing, which is used to monitor the resistance of liftgate
travel. This speed reading also allows the power liftgate
control module to detect obstructions and move the lift-
gate accordingly. The engage actuator is used to toggle
between power open/close mode and full manual mode
when desired. The full open switch is used to let the
power liftgate control module know when the liftgate is
approaching the full open position.
Serviceable components of the power liftgate gear/mo-
tor assembly are the complete gear/motor assembly,
motor and wire harness, lift gear and control rod,
engage actuator, full open switch and the transverse
bracket.
OPERATION
With the push of a power liftgate command switch
(liftgate closed), the power liftgate control module
will signal the latch assembly to release the liftgate
from its primary closed and latched position to the
released and movable position. The liftgate motor-
mounted engage actuator then engages the liftgatemotor assembly, which moves the liftgate into the
open position. The liftgate motor provides the torque
and power to move the door to its full open or closed
position(Refer to 8 - ELECTRICAL/POWER DOORS -
OPERATION) for additional information.
REMOVAL
The power liftgate gear/motor assembly is serviced
in two ways: the complete gear/motor assembly, or
the motor, aluminum housing, drive gears and wire
harness assembly. To perform this service, use the
following procedure to remove the gear/motor assem-
bly from the vehicle. Then refer to the other proce-
dures called out in this section to transfer the
remaining components (engage actuator, full open
switch, transverse bracket and lift gear and rod) to
the replacement gear/motor assembly.
(1)
Disconnect and isolate the battery negative cable.
(2) Remove the left rear D-pillar trim panel from
the vehicle, (Refer to 23 - BODY/INTERIOR/LEFT
D-PILLAR TRIM PANEL - REMOVAL).
(3) Disconnect the wire harness connector from the
motor assembly (Fig. 15).
(4) Remove the two bolts from the motor housing
and the one bolt from the transverse mount bracket.
(5) Grab the liftgate motor assembly and lift
upward and out to unhook the motor assembly from
the D-pillar.
(6) Remove the liftgate motor assembly from the
vehicle.
Fig. 14 POWER LIFTGATE COMPONENTS
1 - POWER LIFTGATE GEAR MOTOR/ASSEMBLY
2 - POWER LIFTGATE CONTROL MODULE
3 - ELECTRICAL GROUND LOCATION
Fig. 15 POWER LIFTGATE COMPONENTS
1 - POWER LIFTGATE GEAR MOTOR/ASSEMBLY
2 - POWER LIFTGATE CONTROL MODULE
3 - ELECTRICAL GROUND LOCATION
RSPOWER LIFTGATE SYSTEM8N-15

INSTALLATION
(1) Using the motor housing tab, hook the liftgate
motor assembly on the D-pillar.
(2) Install the three motor assembly retaining
bolts. Torque the two rear most bolts first to 9.5 N´m
(85 in. lbs.). Torque the remaining bolt next to the
window actuator to 9.5 N´m (85 in. lbs.).
(3) Connect the liftgate motor assembly electrical
connector.
(4) Install the D-pillar trim panel on the vehicle,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(7) Verify power liftgate system operation. Cycle
the power liftgate through one complete open and
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components.
LIFT GEAR & LINK ROD
DESCRIPTION
The lift gear and rod assembly are located in the
left rear of the vehicle and are visible without remov-ing the D-pillar trim (Fig. 16). The lift gear provides
the leverage to move the liftgate from the closed to
the open position. The lift gear attaches to a bearing
on the gear motor assembly with four bolts. On the
outboard side of the lift gear are riveted on teeth,
which mesh with the gear motor assembly drive
gears during a open or close operation. The rod
assembly is a steel shaft, equipped with two spheri-
cal rod ends which attaches the lift gear to the lift-
gate. The lift gear and rod assembly are serviceable
components.
OPERATION
One end of the rod assembly is attached to the lift-
gate, the other attached to the lift gear. When the lift
gear is driven by the gear motor assembly the lift-
gate is moved to the open or closed position.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the left rear D-pillar trim panel from
the vehicle, (Refer to 23 - BODY/INTERIOR/LEFT
D-PILLAR TRIM PANEL - REMOVAL).
(3) Remove the lift gear retaining bolts (Fig. 17).
(4) Remove the lift gear and rod from the vehicle.
Fig. 16 LIFTGATE GEAR/MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 17 LIFTGATE GEAR MOTOR ASSEMBLY
1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - LIFT GEAR RETAINING BOLTS
8N - 16 POWER LIFTGATE SYSTEMRS
LIFTGATE MOTOR (Continued)

TRANSVERSE BRACKET
DESCRIPTION
The transverse bracket (Fig. 22) is used to support
and secure the power liftgate gear/motor assembly to
the left rear body D-pillar. The transverse bracket is
a serviceable power liftgate component.
OPERATION
The power liftgate transverse bracket supports the
gear motor assembly by supplying an additional
attachment point. Located on the leading edge of the
gear motor assembly, one end of the transverse
bracket attaches to the motor assembly the other to
the leading edge of the vehicles D-pillar.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the left D-pillar trim from the vehicle,
(Refer to 23 - BODY/INTERIOR/LEFT D-PILLAR
TRIM PANEL - REMOVAL).
(3) Disconnect the gear motor assembly electrical
connector and disengage retaining pushpin.
(4) Loosen the gear motor assembly retaining bolts
to allow room for transverse bracket to be removed.
(5) Remove the transverse bracket retaining bolts
(Fig. 23).
(6)
Remove the transverse bracket from the vehicle.
INSTALLATION
(1) Position the transverse bracket in the vehicle.
Be certain the transverse bracket is properly posi-
tioned. The bracket should just touch the engage
actuator arm and be positioned between the actuator
arm and the motor housing.
(2) Torque the transverse bracket retaining bolts
to the gear motor assembly to 9.5 N´m (85 in. lbs.).
Do not tighten the transverse bracket retaining bolt,
located under the window actuator at this time.
(3) Torque the gear motor assembly retaining bolts
to 9.5 N´m (85 in. lbs.).
(4) Torque the final transverse bracket retaining
bolt to 9.5 N´m (85 in. lbs.).
(5) Connect the gear motor assembly electrical con-
nector and engage retaining pushpin.
(6) Install the left D-pillar trim, (Refer to 23 -
BODY/INTERIOR/LEFT D-PILLAR TRIM PANEL -
INSTALLATION).
(7) Connect the battery negative cable.
(8) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes related to the door motor assembly.
(9) Verify power liftgate system operation. Cycle
the power liftgate through one complete open and
close cycle, this will allow the power liftgate control
module to relearn its cycle with the new components.
Fig. 22 LIFTGATE GEAR/MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Fig. 23 LIFTGATE GEAR MOTOR ASSEMBLY
1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
RSPOWER LIFTGATE SYSTEM8N-19

The lock function works from the RKE transmitter
even in an out of synchronization condition, therefore
it could be verified by pressing the LOCK button on
the RKE key fob.
DOOR CYLINDER LOCK
SWITCH - EXPORT
DESCRIPTION
The Door Cylinder Lock Switch (If equipped) is
used to:
²Unlock/Lock all the doors via the Central Lock-
ing feature.
²Arm/Disarm the Vehicle Theft Security System.
²Trigger the Illuminated Entry feature.
The door cylinder lock switch is mounted to the
rear of the driver door lock cylinder. When installed
on the rear of the cylinder, there is a tab on the lock
cylinder that aligns with the switch to prevent it
from turning. An anti-rotating device. The door cylin-
der lock switch is a one time use switch. Once it is
removed from the rear of the door lock cylinder, it
may not be reinstalled and a new switch must be
used.
OPERATION
When the Door Cylinder Lock Switch is turned
either way using the door key cylinder, the BCM
reads a direct message signal from the switch.
If turning the key cylinder once, toward the front
of the vehicle, this will:
(1) Mechanically unlock the door lock.
(2) Disarm the Vehicle Theft Security System (if
equipped).
(3) Turn on the Illuminated Entry (if equipped) for
approximately 30 seconds.
If the key cylinder is turned to the unlock position
(toward the front of vehicle) twice within two sec-
onds, all the doors and liftgate will unlock (if
equipped with the central locking feature).
To lock the vehicle using the door cylinder lock
switch, turn the key cylinder toward the rear of the
vehicle once. This will lock the door that you are
using the key on. If equipped with the central locking
feature, this will lock all the other doors and liftgate.
Furthermore, this will arm the vehicle theft security
system and turn off the illuminated entry.
DIAGNOSIS AND TESTING
DOOR CYLINDER LOCK SWITCH - EXPORT
Any diagnosis of the power lock system
should begin with the use of the DRB IIItdiag-
nostic tool. For information on the use of theDRB IIIt, refer to the appropriate Diagnostic
Service Manual.
For complete circuit diagrams, refer to the appro-
priate wiring information.
(1) Visually inspect the switch for proper installa-
tion. Make sure it is seated on the rear of the key
cylinder, with the tab of the door key cylinder prop-
erly aligned with the slot on the door cylinder lock
switch.
(2) Disconnect the switch at the harness connector
and check the resistance in each switch position.
CAUTION: Do not disconnect the switch from the
rear of the door key cylinder. This switch is a one
time use switch. Once it is removed from the rear of
the switch, it is not reusable and must be replaced.
Test the switch at the harness connector.
DOOR CYLINDER LOCK SWITCH RESISTANCE
SWITCH POSITION RESISTANCE VALUE
COUNTERCLOCKWISE 5.4K OHMS
NEUTRAL 18.4K OHMS
CLOCKWISE 2K OHMS
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel of the effected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - REMOVAL).
(3) Close the door window.
(4) Disconnect the door cylinder lock switch wire
connector from the door harness, and wiring clip
from the impact beam.
(5) Remove the outer door handle from the door.
(6) Remove the switch from the key cylinder in the
door handle and remove from vehicle.
INSTALLATION
(1) Install the switch on the key cylinder in the
door handle.
(2) Install the door handle.
(3) Connect the door cylinder lock switch wire con-
nector to the door harness, and the wiring clip to the
impact beam.
(4) Install the door trim panel of the affected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Verify system operation.
8N - 22 POWER LOCKSRS
POWER LOCKS (Continued)