headlamp CHRYSLER VOYAGER 2001 Service Manual

Component/Ground Color Location Fig.
Boost Pressure Sensor (Diesel) BK Top Left of Engine N/S
Brake Fuid Level Switch BK On Master Cylinder 7
Brake Lamp Switch BK At Top Of Brake Pedal 31, 32
Brake Transmission Shift
Interlock Solenoid (EATX)BK Near Steering Column 16, 17, 18,
26
C100 BK Left Fender Shield 6
C101 LTGY Left Fender Shield 6
C102 (2.4L) BK Top Front of Engine 11
C102 (3.3/3.8L) BK At Fuel Rail 14
C103 (Diesel) BK Left Side Engine Compartment N/S
C106 (BUX) BK Near Left Headlamp Leveling Motor N/S
C107 (BUX) BK Near Right Headlamp Leveling Motor N/S
C200 GY Left Side Instrument Panel 16, 17, 25,
31, 32
C201 YL Left Side Instrument Panel 16, 17, 25,
31, 32
C202 GY Right Side Instrument Panel A/C Heatrer Unit 16, 20, 25
C203 (United Kingdom) WT Right Side of Instrument Panel N/S
C300 BK Left Front Door Lower N/S
C301 LTGY Left Front Door Upper N/S
C302 LTGY Right Front Door Upper 9, 29, 33
C303 BK Right Front Door Lower 9, 29, 33
C304 YL Left Wire Track Seat to Body 27
C305 GY Left Wire Track Seat to Body 27
C306 YL Right Wire Track Seat to Body 28
C307 GY Right Wire Track Seat to Body 28
C308 BL Left Rear Sliding Door 30
C309 GN Right Rear Sliding Door 27, 28, 29
C310 BK At Front Console N/S
C311 GY Rear A/C Switch N/S
C312 GY At Dome Lamp 28, 29
C313 BK At Rear Console N/S
C314 BK Left Side Liftgate 38
C315 BK Right Side Liftgate 38
C316 BK Wire Track to Sliding Door N/S
C317 BK Right Sliding Door 27, 34
C318 (Trailer Tow) BK Left Quarter N/S
C319 (Except Built-up Export) Left Side Liftgate N/S
C320 DKGY Driver Power Seat on Seat Harness N/S
C321 DKGY Under Passenger Seat N/S
C322 BK On Seat Harness to Body 27
C324 BK Left Sliding Door N/S
C325 BK Right Sliding Door 27
8Wa - 90 - 2 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Component/Ground Color Location Fig.
Fuel Injector No.1 (Diesel) BK At Fuel Injector 12
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK 12
Fuel Injector No.3 BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK 12
Fuel Injector No.4 BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK 12
Fuel Injector No.5 BK At Fuel Injector N/S
Fuel Injector No.6 BK At Fuel Injector N/S
Fuel Tank Module LTGY Side of Fuel Tank N/S
Fuel Rail Pressure Sensor
(Diesel)BK Top Left of Engine 12
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 11
G102 Left Headlamp Area N/S
G103 Above Starter 11
G200 Right Side of Instrument Panel 16, 20, 25
G201 Right Side of Instrument Panel 16, 20, 25
G300 Left B Pillar 27
G301 Right B Pillar 28, 29
G302 Left Rear Quarter N/S
G400 Liftgate Ground 38
Generator BK Rear of Generator 11, 12, 14,
15
Glove Box Lamp BL Rear of Glove Box 19, 25
Glow Plug Relay (Diesel) BK At Relay N/S
Halo Lamp WT Steering Column 16, 17, 18,
19, 26
Headlamp Switch BK Rear of Switch 16, 17, 25
Headlamp Washer Pump Motor At Motor
High Note Horn BK Left Frame Rail 6
High Pressure Fuel Pump
(Diesel)Rear of Pump
Hood Ajar Switch BK Left Fender 7
Idle Air Control Motor (2.4L) BK On Throttle Body 10
Idle Air Control Motor (3.3/3.8L) BK On Throttle Body 14
Ignition Coil Pack 2.4L BK Top of Valve Cover 10, 11
Ignition Coil Pack 3.3L, 3.8L DKGY Top of Engine 15
Ignition Switch BK Rear of Switch at Steering Column 16, 17 18,
19, 26
Inlet Air Temperature Sensor BK Top Left of Engine 14
Instrument Cluster BK Rear of Cluster 16, 17, 23
Instrument Panel Switch Bank BK Right Center of Instrument Panel 16, 19, 21
RG8W-90 CONNECTOR/GROUND LOCATIONS BUX8Wa-90-5
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Component/Ground Color Location Fig.
Instrument Panel Power Outlet NAT Center of Instrument Panel 16, 19, 21
Intelligent Power Module C1 LTGN Left Fender Shield 8
Intelligent Power Module C2 GN/BL Left Fender Shield 8
Intelligent Power Module C3
(Diesel)YL/RD Left Fender Shield 8
Intelligent Power Module C3
(Gas)NAT/RD Left Fender Shield 8
Intelligent Power Module C4 BL Left Fender Shield 8
Intelligent Power Module C5 BK Left Fender Shield 8
Intelligent Power Module C6 NAT Left Fender Shield 8
Intelligent Power Module C7 BK/RD Left Fender Shield 8
Intelligent Power Module C8 OR Left Fender Shield 8
Intelligent Power Module C9 BK Left Fender Shield 8
Knock Sensor GY Front of Cylinder Block
Leak Detection Pump LTGY At Pump 10, 11, 15
Left B Pillar Switch GY Left B Pillar 30
Left Cinch/Release Motor GY Left Sliding Door N/S
Left Combination Relay BK Left Rear Quarter Panel N/S
Left Cylinder Lock Switch BK At Switch N/S
Left Door Speaker BK At Speaker N/S
Left Fog Lamp WT At Lamp N/S
Left Front Door Ajar Switch BK At Switch N/S
Left Front Door Lock Motor/Ajar
SwitchBK Left Door N/S
Left Front Park/Turn Signal Lamp BK At Lamp 1, 6
Left Front Wheel Speed Sensor BK Left Fender Side Shield N/S
Left Full Open Switch BK Left Sliding Door N/S
Left Headlamp BK At Lamp 1, 6
Left Headlamp Leveling Motor WT At Motor N/S
Left High Beam Lamp BK At Lamp N/S
Left Instrument Panel Speaker BK At Speaker 16, 17, 22
Left Lavalier Module BK At Module N/S
Left Liftgate Flood Lamp GY At Lamp 38
Left Low Beam Lamp BK At Lamp N/S
Left Mid Reading Lamp GY At Lamp N/S
Left Park Lamp BK At Lamp N/S
Left Power Mirror BK At Mirror 22
Left Rear Door Ajar Switch GY Left C Pillar N/S
Left Rear Lamp Assembly BK At Lamp 36
Left Rear Reading Lamp BK At Lamp N/S
Left Rear Speaker BK At Speaker 36
Left Rear Vent Motor NAT At Motor 35, 36
Left Rear Wheel Speed Sensor BK Center Rear of Floor Pan 36
8Wa - 90 - 6 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Component/Ground Color Location Fig.
Right Door Speaker BK/RD At Speaker N/S
Right Fog Lamp WT At Lamp 4
Right Front Door Ajar Switch BK At B Pillar N/S
Right Front Door Lock Motor/Ajar
SwitchRight Front Door 33
Right Front Park/Turn Signal
LampBK At Lamp 1, 4
Right Front Wheel Speed Sensor BK Right Fender Side Shield 10, 13, 14
Right Full Open Switch BK Right Sliding Door 34
Right Headlamp BK At Lamp 1, 4
Right Headlamp Leveling Motor WT At Right Headlamp N/S
Right High Beam Lamp BK At Right Headlamp N/S
Right Instrument Panel Speaker BK At Speaker 16, 19, 20
Right Lavalier Module BK At Module 2
Right Liftgate Flood Lamp BK At Lamp 38
Right Low Beam Lamp BK At Right Headlamp N/S
Right Mid Reading Lamp GY At Lamp N/S
Right Park Lamp BK AT Lamp N/S
Right Power Mirror BK At Mirror 16, 20, 23
Right Rear Lamp Assembly BK At Lamp 37
Right Rear Pillar Speaker BK At Speaker 37
Right Rear Reading Lamp GY At Lamp N/S
Right Rear Speaker BK At Speaker 37
Right Rear Vent Motor NAT At Motor 37
Right Rear Wheel Speed Sensor BK Center Rear of Floor Pan 37
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater GY Right Front Fender 29
Right Seat Airbag YL At Passenger Seat N/S
Right Side Impact Airbag Control
ModuleYL Right B Pillar 29
Right Sliding Door Control
Module C1BK Rear of Door 34, 35
Right Sliding Door Control
Module C2BK/RD Rear of Door 34, 35
Right Sliding Door Latch Sensing
SwitchBK At Sliding Door 34
Right Sliding Door Lock Motor BK Rear of Door 34
Right Sliding Door Lock
Motor/Ajar SwitchBK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 34
Right Speed Control Switch BK At Steering Wheel N/S
Right Stop/Turn Signal Relay BK LT Quarter Panel N/S
Right Turn Signal Lamp OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
8Wa - 90 - 10 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Fig. 1 HEADLAMP CONNECTORS
8Wa - 90 - 12 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies. Refer to
group 8 exterior lighting.
(3) Remove two bolts attaching the upper grill sup-
port to the headlamp mounting panel at each side of
the grille.
(4) Hoist vehicle and support with safety stands.
(5)
Remove front wheels. Refer to Group 22, Wheels
and Tires, for proper procedures and sequence.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts holding front
fascia to fender. Refer to Group 23, Body, for proper
procedures.
(7) Remove the two bolts and two nuts holding fas-
cia to the front fenders (Fig. 1).
(8) Remove the five bolts holding bottom of fascia/
air dam to radiator closure panel.
(9) Disconnect fog lamp/parking and turn signal
lamp wire connector, as necessary.
(10) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Lower vehicle.
(3) Install the two bolts to hold fascia to headlamp
mounting panel at each side of grille.(4) Raise vehicle.
(5) Install the two bolts and two nuts to hold fas-
cia to the front fenders (Fig. 1). The fascia should be
flush to fender.
(6) Install front wheelhouse splash shields fasten-
ers. Refer to Group 23, Body, for proper procedures.
(7) Install front wheels. Refer to Group 22, Wheels
and Tires, for proper procedures and tightening
sequence.
(8) Install the five bolts to hold bottom of fascia to
radiator closure panel.
(9) Lower the vehicle.
(10) Install the headlamp assemblies. Refer to sec-
tion 8 for installation.
FRONT BUMPER
REINFORCEMENT
REMOVAL
(1) Remove front bumper fascia. (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL)
(2) Support front bumper reinforcement on a suit-
able lifting device.
(3) Remove the four nuts holding front bumper
reinforcement to frame rail (Fig. 2).
(4) Remove front bumper reinforcement from vehicle.
Fig. 1 FRONT BUMPER FASCIA
1 - FRONT BUMPER FASCIA
2 - FRONT BUMPER REINFORCEMENT
3 - RADIATOR ENCLOSURE
Fig. 2 FRT BUMPER REINFORCEMENT
1 - FRONT BUMPER REINFORCEMENT
2 - FRAME RAILS
13 - 2 FRAMES & BUMPERSRS

SPECIFICATIONS
ITEM LOCATION GAP FLUSH
A HOOD TO FASCIA (VOYAGER ONLY)
8.0   2.0
PARALLEL WITHING 2.0 RIGHT TO
LEFT2.5 OVERFLUSH TO HOOD  
1.5 CONSISTENT WITHIN 2.0
B HEADLAMP MODULE TO
HOOD8.0   2.0
PARALLEL WITHIN 2.0 RIGHT TO
LEFT
C HOOD TO FENDER (FOR &
AFT)0.0   1.5
LEFT TO RIGHT WITHIN 1.5
D HOOD TO FENDER 4.0   1.5
PARALLEL WITHIN 2.5WITHIN 1.5
LEFT TO RIGHTUNDERFLUSH
  2.0
E FENDER TO DOOR 5.0   1.5
PARALLEL WITHIN 2.0UNDERFLUSH 0.5   1.5
CONSISTENT WITHIN 2.0
F FRONT DOOR TO9A9PILLAR
COVERUNDERFLUSH 0.5   2.0
G9A9PILLAR COVER TO
SLIDING DOOR5.0   PARALLEL WITHIN 1.0 1.0 UNDERFLUSH  
CONSISTENT WITHIN 3.0
H FRONT DOOR APPLIQUE TO
SLIDING DOOR GLASS5.0   2.0
PARALLEL WITHIN 2.01.0 UNDERFLUSH   2.0
CONSISTENT WITHIN 3.0
I FRONT DOOR TO SLIDING
DOOR5.0   2.0
PARALLEL WITHIN 2.0  2.0 CONSISTENT WITHIN
2.0
J SLIDING DOOR TO REAR
APERTURE GLASS5.0   2.0
PARALLEL WITHIN 1.5  3.0 CONSISTENT WITHIN
3.0
K SLIDING DOOR TO REAR
APERTURE5.0   1.5
PARALLEL WITHIN 2.0  1.5 CONSISTENT WITHIN
1.5
L TAILLAMP TO BODY SIDE
APERTURE1.0   1.0
PARALLEL WITHIN 1.5OVERFLUSH
M TAILLAMP TO LIFTGATE 4.0   2.0 OVERFLUSH
N LIFTGATE TO BODY SIDE
APERTURE4.0   1.5 UNDERFLUSH 1.0   2.5
CONSISTENT WITHIN 2.0
O LIFTGATE TO ROOF 8.0   2.0   1.5
P LIFTGATE TO FASCIA 8.0   2.5
PARALLEL WITHIN 3.0
Q LIFTGATE TO REAR FASCIA UNDERFLUSH TO 1.0
MAXIMUM OVERFLUSH
R FUEL FILLER DOOR TO BODY
SIDE APERTUREUNDERFLUSH 0.5   1.0
NOTE: All measurements are in mm.
23 - 12 BODYRS
BODY (Continued)

HEADLAMP MOUNTING PLATE
23 - 70 BODYRS
BODY (Continued)

EXTERIOR NAME PLATES -
TAPE ATTACHED
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) Using a nonmetallic prying device, such as a
plastic or wood trim stick gently pry up at corners
and remove.
(4) Clean off all traces of adhesive or double sided
tape from the panel with a general purpose adhesive
remover.
INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Align badgeing to reference points.
(3) Install and press securely to full adhesive con-
tact
(4) Clean away any reference points.
EXTERIOR NAME PLATES -
ADHESIVE ATTACHED
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) With your fingernail lift up and peel away
badgeing/tape from panel, using a heat gun as you
go.
(4) Clean off all traces of adhesive from the pan-
el(s) with a general purpose adhesive remover.
INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Remove paper carrier and align badgeing/tape
to reference points or adjacent panel.
(3) Install and press securely, using a plastic
spreader to eliminate all air bubbles.
(4) Remove top protective carrier.
(5) Clean away any reference points.
FRONT FENDER
REMOVAL
(1) Remove headlamp housing. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - REMOVAL)
(2) Remove mud guard.
(3) Remove inner splash shield.
(4) Remove fender to fascia nuts.(5) Remove outboard cowl grille/fender bracket
screw.
(6) Remove fender bolt to lower rocker panel.
(7) Remove fender bolt to lower cowl.
(8) Pull fascia away from fender.
(9) Remove bolts attaching fender to upper rail.
(10) Remove fender from vehicle (Fig. 8).
INSTALLATION
(1) Place fender in position on vehicle.
(2) From inside engine compartment, start the
center upper rail bolt. install all the bolts attaching
fender to upper rail and tighten.
(3) Install fender to lower cowl panel bolt.
(4) Install fender to rocker panel bolt.
(5) Place fascia into position.
(6) Install outboard cowl grille/fender bracket
screw.
(7) Install fender to fascia nuts.
(8) Install inner splash shield.
(9) Install mud guard.
(10) Install headlamp assembly. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - INSTALLATION)
(11) Check fender for flush and gap.
FUEL FILL DOOR
REMOVAL
(1) Remove left quarter trim panel.
Fig. 8 Fender
1 - FASTENERS
2 - FENDER
3 - FASTENERS
RSEXTERIOR23 - 191

A/C PRESSURE TRANSDUCER
DESCRIPTION
The A/C pressure transducer (Fig. 2) is a switch
that is installed on a fitting located on the refriger-
ant liquid line between the filter-drier and the
expansion valve in the right rear corner of the engine
compartment. An internally threaded hex fitting on
the transducer connects it to the externally threaded
Schrader-type fitting on the liquid line. A rubber
O-ring seals the connection between the transducer
and the liquid line fitting. Three terminals within a
molded plastic connector receptacle on the top of the
transducer connect it to the vehicle electrical system
through a take out and connector of the headlamp
and dash wire harness.
The A/C pressure transducer cannot be adjusted or
repaired and, if faulty or damaged, it musty be
replaced.
OPERATION
The A/C pressure transducer monitors the pres-
sures in the high side of the refrigerant system
through its connection to a fitting on the liquid line.
The transducer will change its internal resistance in
response to the pressures it monitors. The Power-
train Control Module (PCM) provides a five volt ref-
erence signal and a sensor ground to the transducer,
then monitors the output voltage of the transducer
on a sensor return circuit to determine refrigerant
pressure. The PCM is programmed to respond to thisand other sensor inputs by controlling the operation
of the air conditioning compressor clutch and the
radiator cooling fan to help optimize air conditioning
system performance and to protect the system com-
ponents from damage. The A/C pressure transducer
input to the PCM will also prevent the air condition-
ing compressor clutch from engaging when ambient
temperatures are below about 10É C (50É F) due to
the pressure/temperature relationship of the refriger-
ant. The Schrader-type valve in the liquid line fitting
permits the A/C pressure transducer to be removed
or installed without disturbing the refrigerant in the
system. The A/C pressure transducer is diagnosed
using a DRBIIItscan tool. Refer to the appropriate
diagnostic information.
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER
The A/C pressure transducer is tested using a
DRBIIItscan tool. Refer to the appropriate diagnos-
tic information. Before testing the A/C pressure
transducer, be certain that the transducer wire har-
ness connection is clean of corrosion and properly
connected. For the air conditioning system to operate,
an A/C pressure transducer voltage reading between
0.451 and 4.519 volts is required. Voltages outside
this range indicate a low or high refrigerant system
pressure condition to the Powertrain Control Module
(PCM). The PCM is programmed to respond to a low
or high refrigerant system pressure by suppressing
operation of the compressor. Refer to the A/C Pres-
sure Transducer Voltage table for the possible condi-
tion indicated by the transducer voltage readings.
A/C PRESSURE TRANSDUCER VOLTAGE
VOLTAGE POSSIBLE INDICATION
0.0 1. NO SENSOR SUPPLY
VOLTAGE FROM PCM.
2. SHORTED SENSOR CIRCUIT.
3. FAULTY TRANSDUCER.
0.150 TO 0.450 1. AMBIENT TEMPERATURE
BELOW 10É C (50É F).
2. LOW REFRIGERANT
SYSTEM PRESSURE.
0.451 TO 4.519 1. NORMAL REFRIGERANT
SYSTEM PRESSURE.
4.520 TO 4.850 1. HIGH REFRIGERANT
SYSTEM PRESSURE.
5.0 1. OPEN SENSOR CIRCUIT.
2. FAULTY TRANSDUCER.
Fig. 2 A/C Pressure Transducer
1 - RIGHT FRONT STRUT TOWER
2 - CONNECTOR
3 - A/C PRESSURE TRANSDUCER
4 - RIGHT WIPER MODULE DRAIN TUBE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
24 - 10 CONTROLS - FRONTRS