Security CHRYSLER VOYAGER 1996 Service Manual

GROUP TAB LOCATOR
Introduction
0Lubrication and Maintenance
2Suspension
5Brakes
6Clutch
7Cooling System
8ABattery
8BStarting System
8EInstrument Panel and Systems
8HVehicle Speed Control System
8KWiper and Washer Systems
8LLamps
8QVehicle Theft/Security Systems
8UChime Warning/Reminder System
8WWiring Diagrams
9Engine
13Frame and Bumpers
14Fuel SystemÐ2.5L Diesel Engine/2.0L Gas Engine
19Steering
21AÐ598 Manual Transaxle
23Body
24Heating and Air Conditioning
25Emission Control System

BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 25SPECIFICATIONS
EXTERIOR LAMP BULBS.................. 25
INTERIOR LAMP BULBS.................. 25
GENERAL INFORMATION
INTRODUCTION
The following Bulb Application Tables list the lamp
title on the left side of the column and trade number
or part number on the right.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
If a halogen bulb is contaminated with oil, clean
bulb with denatured alcohol or ammonia based sol-
vent.
SPECIFICATIONS
EXTERIOR LAMP BULBS
LAMP BULB
Back-up...............................3057
CHMSL................................921
Fog Lamp...............................H3
FogLamp±T&C ........................9040
Headlamp..............................9007
Headlamp high beam ± T&C...............9005
Headlamp low beam ± T&C............9005 SLL
License Plate............................168
Parking/Turn Signal/Front Side Marker. . . .3157NA
Parking/Turn Signal ± T&C............4157NAK
Tail, Stop, Turn Signal and Side Marker......3057
Front Side Marker......................194NA
INTERIOR LAMP BULBS
LAMP BULB
ABS.................................PC194
AirBag ..............................PC194
Alarm Set (Security)....................PC194
Brake Warning.........................PC194
Center/Rear Reading Lamps.................578
Center/Rear Dome Lamps...................579
Check Engine Ind.......................PC194
Front Door Courtesy.......................567
Door Ajar Ind..........................PC194
Front Header Reading Lamp................567
Glove Box Lamp..........................194
High Beam Ind.........................PC194
Instrument Cluster.....................PC194
IP Bin/Ash Tray..........................161
Liftgate Flood Lamps......................567
Liftgate Ajar Ind.........................PC74
Low Fuel Ind..........................PC194
Oil Pressure Ind........................PC194
O/H Console Reading Lamps................579
Seat Belt Ind...........................PC74
Engine Temp Ind.......................PC194
Turn Signal...........................PC194
Engine Compartment Lamps................579
Visor Vanity Lamp....................6501966
Low Washer Fluid.......................PC74
Low Volts Warning.......................PC74
Cruise Indicator........................PC194
NSLAMPS 8L - 25

BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION....................... 17
CLEANING AND INSPECTION
HEADLAMP CLEANING.................. 17SPECIFICATIONS
EXTERIOR LAMP BULBS................. 17
INTERIOR LAMP BULBS................. 17
GENERAL INFORMATION
INTRODUCTION
The following Bulb Application Tables list the lamp
title on the left side of the column and trade number
or part number on the right.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
If a halogen bulb is contaminated with oil, clean
bulb with denatured alcohol or ammonia based sol-
vent.
CLEANING AND INSPECTION
HEADLAMP CLEANING
This vehicle is equipped with plastic headlights
that are lighter and less susceptible to stone break-
age than glass headlights.
This plastic is not as scratch resistant as glass and
therefore a different lens cleaning procedures must
be followed.
To minimize the possibility of scratching the lenses
and reducing light output, avoid wiping with a dry
cloth. To remove road dirt, wash with a mild soap
solution followed by rinsing with water.
Do not use abrasive cleaning components, solvents,
steel wool or other aggressive material to clean the
lenses.
SPECIFICATIONS
EXTERIOR LAMP BULBS
LAMP BULB
Back-up.............................P21W
CHMSL (Non-Solar Tint)................P21W
CHMSL (Solar Tint)....................R10WLAMP BULB
Fog Lamp..............................H3
Headlamp..............................H4
License Plate..........................C5W
Front Turn Signal....................PY21W
Citylight..............................T4W
Front Side Repeater.....................T4W
Tail, Stop...........................P21/5W
Rear Turn Signal......................P21W
Rear Fog Lamp........................P21W
INTERIOR LAMP BULBS
LAMP BULB
ABS ................................PC194
AirBag .............................PC194
Alarm Set (Security/Immobilzer)..........PC194
Brake Warning.......................PC194
Center/Rear Reading Lamps...............578
Center/Rear Dome Lamps.................579
Cruise Indicator.......................PC194
Door Ajar Indicator....................PC194
Engine Compartment Lamps...............579
Engine Temp Indicator.................PC194
Front Door Courtesy......................567
Glove Box Lamp.........................194
Glow Plug Indicator (Diesel Engine Only) . . . PC194
High Beam Indicator...................PC194
Instrument Cluster....................PC194
IP/Ash Tray (Left Hand Drive Only).........161
Liftgate Flood Lamps.....................567
Liftgate Ajar Indicator...................PC74
Low Coolant Level (Diesel Engine Only).....PC74
Low Fuel Indicator....................PC194
Low Volts Warning.....................PC74
Low Washer Fluid......................PC74
Oil Pressure Indicator..................PC194
O/H Console Reading Lamps...............579
Seat Belt Indicator (Except Diesel).........PC74
Service Engine Soon...................PC194
Turn Signal..........................PC194
Visor Vanity Lamp...................6501966
NS/GSLAMPS 8L - 17

REMOTE KEYLESS ENTRY
INDEX
page page
DESCRIPTION AND OPERATION
INTRODUCTION......................... 5
VEHICLE ACCESS CODE (VAC)
PROGRAMMING........................ 5
DIAGNOSIS AND TESTING
RKE DIAGNOSTICS....................... 5
SERVICE PROCEDURES
HORN CHIRP DISABLE OR ENABLE.......... 6REMOVAL AND INSTALLATION
RKE MODULE........................... 6
ADJUSTMENTS
PROGRAMMING RKE MODULE.............. 6
SPECIFICATIONS
RKE TRANSMITTER BATTERY.............. 6
RKE TRANSMITTER RANGE................ 6
DESCRIPTION AND OPERATION
INTRODUCTION
The key fob transmitter has three buttons to actu-
ate and program the Remote Keyless Entry (RKE)
system (Fig. 1).
²UNLOCK: Pressing the UNLOCK button once
will unlock the driver door and activate the illumi-
nated entry system and disarm Vehicle Theft Secu-
rity System, if equipped. Pressing the UNLOCK
button twice within five seconds will unlock all doors
and activate the illuminated entry system.
²LOCK: Pressing the LOCK button locks all
doors and sounds horn (chirp) and arm the Vehicle
Theft Security System. The chirp verifies the door
lock operation.
²PANIC: Pressing the PANIC button sounds the
horns at half second intervals, flashes the exterior
lamps, and turns ON the interior lamps. The panic
alarm will remain on for three minutes, or until the
PANIC button is actuated again or the ignition
switch is turned to the RUN position.
²The Remote Keyless Entry Module is capable of
retaining the transmitter Vehicle Access Code(s)
(VAC) in its memory even after vehicle power has
been interrupted.
²The RKE system activates the optional memory
seat and mirror system, if equipped. Two primary
key fob transmitters can be programmed to actuate
memory seat and mirror setting 1 or 2. Two addi-
tional key fob transmitters can be added, but they
will not be able to operate the memory seat and mir-
ror system. Refer to Group 8R, Power Seats and
Group 8T, Power Mirrors for memory system infor-
mation.
VEHICLE ACCESS CODE (VAC) PROGRAMMING
The RKE module is capable of retaining up to four
different Vehicle Access Codes. Whenever the vehicle
battery power is interrupted the RKE Module willretain all vehicle access codes in its memory. When
replacing or adding a key fob transmitter (maximum
4) a functional key fob transmitter is required to pro-
gram the RKE Module to accept the new Vehicle
Access Code. If a functional key fob transmitter is
not available, a scan tool (DRB) can be used to pro-
gram the RKE Module. Refer to the proper Body
Diagnostic Procedures manual for Vehicle Access
Code programming procedures using a scan tool.
DIAGNOSIS AND TESTING
RKE DIAGNOSTICS
Refer to Group 8W, Wiring Diagrams for circuit
information and component locations. Refer to the
proper Body Diagnostic Procedures manual for test-
ing the Remote Keyless Entry system using a scan
tool (DRB). Also refer to other interrelated systems
groups within this manual:
²Group 8Q, Vehicle Theft Security System
²Group 8R, Power Seats
²Group 8T, Power Mirrors
Fig. 1 Key Fob Transmitter
NSPOWER DOOR LOCKS 8P - 5

SERVICE PROCEDURES
HORN CHIRP DISABLE OR ENABLE
The horn chirp can be DISABLED or ENABLED
using the following procedure.
To DISABLE (cancelling) the horn chirp feature,
press and hold the transmitter LOCK button for a
minimum four seconds. While pressing LOCK button
in, press the UNLOCK button. The horn chirp fea-
ture will not function until the above procedure is
repeated. To ENABLE (reinstate) the horn chirp fea-
ture, use any one of the four key fob transmitters
and reverse the above procedures. It will ENABLE
the horn chirp feature for all transmitters.
REMOVAL AND INSTALLATION
RKE MODULE
REMOVAL
(1) Remove instrument panel top cover. Refer to
Group 8E, Instrument Panel and Gauges for proper
procedures.
(2) Remove screws holding RKE module to instru-
ment panel.
(3) Disconnect wire connector from RKE module
(Fig. 2).
(4) Remove the RKE module.
INSTALLATION
For installation, reverse the above procedures.
ADJUSTMENTS
PROGRAMMING RKE MODULE
(1) Using a functional key fob transmitter, unlock
the vehicle and disarm the Vehicle Theft Security
System.
(2) Insert ignition key into the ignition switch.
(3) Turn the ignition switch to RUN position with-
out starting engine.
(4) Using a functional key fob transmitter, press
and hold the UNLOCK button for a minimum four
seconds (maximum ten seconds).
(5) While holding UNLOCK button, and before ten
seconds passes, press and release the PANIC button.
A single chime will sound to verify that the RKE
module is set to receive the new Vehicle Access
Code(s).
(6) Within 30 seconds of the chime, press any but-
ton on each new key fob transmitter. After 30 sec-
onds or when ignition switch is turned OFF, the RKE
module will end the programming mode. A single
chime will sound to verify that the RKE module will
no longer receive additional Vehicle Access Code(s).
(7) When Vehicle Access Code(s) programming is
complete, turn Ignition Switch to the OFF position
and verify RKE system operation using each key fob.
NOTE: Only the primary (first two) key fob transmit-
ters will operate the memory seat and mirror sys-
tems. If a primary key fob is being replaced, the
memory seat and mirror module will require pro-
gramming. Refer to Group 8R, Power Seats for
proper (data link) programming procedure.
SPECIFICATIONS
RKE TRANSMITTER BATTERY
The batteries can be removed without special tools
and are readily available at local retail stores. The
recommended battery is Duracell DL 2016 or equiva-
lent. Battery life is about one to two years.
CAUTION: Do not touch the battery terminals or
handle the batteries any more than necessary.
Hands must be clean and dry.
RKE TRANSMITTER RANGE
Normal operation range is up to about a distance
of 7 meters (23 ft.) of the vehicle. Range may be bet-
ter or worse depending on the environment around
the vehicle. Closeness to a radio frequency transmit-
ter such as a radio station tower may degrade oper-
ational range, while range in an open field will be
enhanced.
Fig. 2 RKE Module
8P - 6 POWER DOOR LOCKSNS

VEHICLE THEFT SECURITY SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
ARMING PROCEDURE.................... 1
TIME-OUT PERIOD....................... 2
TRIGGERING THE VTSS................... 2
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES................ 2
REMOVAL AND INSTALLATION
BODY CONTROL MODULE................. 2DOOR LOCK CYLINDER SWITCH............ 2
FRONT DOOR AJAR (VTSS TRIGGER)
SWITCH.............................. 2
HOOD AJAR (VTSS TRIGGER) SWITCH...... 3
LIFTGATE AJAR (VTSS TRIGGER) SWITCH.... 3
LIFTGATE LOCK CYLINDER SWITCH......... 3
SLIDING DOOR AJAR (VTSS TRIGGER)
SWITCH.............................. 4
GENERAL INFORMATION
INTRODUCTION
Vehicles equipped with the Vehicle Theft Security
System (VTSS) system, the doors, liftgate, hood and
ignition circuit are monitored by the Body Control
Module (BCM) when the system is armed. The VTSS
will prevent the engine from starting until the BCM
receives a disarm signal. If the VTSS is triggered,
the horn will pulse, headlamps/marker lamps will
flash, and the VTSS warning lamp will flash. If BCM
determines the threat to be false and the VTSS is not
triggered again, the system will shut down and
rearm itself after three minutes. The VTSS monitor-
ing portion of the system is split into two sections.
The engine compartment section and the passenger
compartment section. If a malfunction occurs in the
engine compartment section, the passenger compart-
ment section would still arm and function normally.
If an electrical malfunction occurs in either section of
the system a Diagnostic Trouble Code (DTC) would
be stored the BCM memory to aid system repair.
DTCs can be retrieved using scan tool (DRB)
attached to the diagnostic connector above the accel-
erator pedal.
ENABLING
To initialize the VTSS feature the operator must,
with the engine compartment hood open, cycle the
key in the liftgate key cylinder to the unlock position
giving the BCM a disarm signal. At this time the
visual alarm outputs the headlamps and marker
lamps will function. However the audio alarm output
the horn and engine disable portion of the VTSS will
not function until there has been twenty consecutiveengine run cycles. When this has occurred the total
VTSS will function.
If during alarm being set the BCM receives a
request from the RKE module to enter PANIC mode
the BCM will cancel the alarm, return VTSS armed
state and then perform the RKE PANIC feature.
DESCRIPTION AND OPERATION
ARMING PROCEDURE
METHOD-A
(1) With the key removed from the ignition lock
and any door open, actuate one of the following:
²Power door lock button to LOCK,
²Key fob LOCK button
²Door lock key cylinder to locked position.
(2) Close all opened doors.
(3) After the last door is closed, an arming time-
out period of sixteen seconds will start, then the
VTSS will become armed.
METHOD-B
Actuating the key fob transmitter LOCK button,
key locking the front doors or liftgate with the doors
closed and the ignition locked will begin the arming
time-out period. If method-A, 16 second time-out
sequence was in process when method-B was actu-
ated, the 16 second time-out will restart from the
time of the second actuation.
If the security lamp does not illuminate at all upon
final door closure, it indicates that the system is not
arming.
The current VTSS status armed or disarmed shall
be maintained in memory to prevent battery discon-
nects from disarming the system.
NSVEHICLE THEFT SECURITY SYSTEM 8Q - 1

TIME-OUT PERIOD
The VTSS requires 16 consecutive seconds to time-
out and arm the alarm. If a door is key unlocked, key
fob unlocked. or the ignition is switched ON, the
VTSS will cancel out. To reset the VTSS, perform
methods A or B.
TRIGGERING THE VTSS
After the VTSS is armed, following actions will
trigger the alarm:
²Opening any door.
²Opening the hood
²Turning the ignition to the ON or unlock posi-
tion.
²The ignition switch can be turned to the acces-
sory position without triggering alarm system.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
Refer to Group 8W, Wiring Diagrams for circuit
information and component locations. Using a scan
tool (DRB). Refer to the proper Body Diagnostic Pro-
cedures manual for test procedures.
REMOVAL AND INSTALLATION
BODY CONTROL MODULE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the lower steering column cover and
the knee blocker reinforcement.
(3) Disconnect the two wire connectors from the
bottom of the Body Control Module (BCM) (Fig. 1).
(4) Remove the bolts holding the Junction Block to
the dash panel mounting bracket.
(5) Remove the Junction Block from the mounting
bracket.
(6) Remove the screws holding BCM to Junction
Block.
(7) Slide the BCM downward to disengage guide
studs on Junction Block from the channels on the
BCM mounting bracket.
(8) Remove the BCM from Junction Block.
INSTALLATION
For installation, reverse the above procedure.
DOOR LOCK CYLINDER SWITCH
REMOVAL
(1) Remove the door trim and water shield.
(2) Close the door window.(3) Disconnect the door lock cylinder switch wire
connector from the door harness and wiring clip from
the impact beam.
(4) Remove the outer handle from the door.
(5) Disengage the lock tab holding switch to the
back of the lock cylinder (Fig. 2).
(6) Remove the switch from the door handle.
INSTALLATION
For installation, reverse the above procedure.
FRONT DOOR AJAR (VTSS TRIGGER) SWITCH
REMOVAL
(1) Open the front door.
(2) Remove the screw holding the door ajar switch
to the door B-pillar (Fig. 3).
(3) Remove the door ajar switch from the B-pillar.
Fig. 1 Body Control Module
Fig. 2 Door Lock Cylinder Switch
8Q - 2 VEHICLE THEFT SECURITY SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

(4) Disconnect the wire connector from the back of
the ajar switch and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
HOOD AJAR (VTSS TRIGGER) SWITCH
REMOVAL
(1) Release the hood latch and open the hood.
(2) Using a small flat blade screws driver, pry trig-
ger switch from top of the radiator closure panel.
(3) Disconnect the trigger switch from the wire
connector and remove the switch (Fig. 4).
INSTALLATION
For installation, reverse the above procedure.
LIFTGATE AJAR (VTSS TRIGGER) SWITCH
REMOVAL
(1) Remove the liftgate latch from the vehicle.
Refer to group 23, Body for proper procedures.
(2) Disconnect the wire connector from the liftgate
ajar switch.
(3) Remove the screw holding the ajar switch to
the liftgate latch and remove the switch (Fig. 5).
INSTALLATION
For installation, Reverse the above procedure.
LIFTGATE LOCK CYLINDER SWITCH
REMOVAL
(1) Remove the inner trim panel from the liftgate.
Refer to Group 23, Body for proper procedure.
(2) Disconnect the door lock cylinder switch wire
connector from the liftgate harness and clip from the
liftgate inner panel.
(3) Remove the outside latch release handle.
(4)
Disconnect the lock tab holding the switch to the
back of lock cylinder and remove the switch (Fig. 6).
INSTALLATION
For installation, reverse the above procedure.
Fig. 3 Front Door Ajar Switch
Fig. 4 Hood Ajar Switch
Fig. 5 Liftgate Ajar switch
Fig. 6 Liftgate Lock Cylinder Switch
NSVEHICLE THEFT SECURITY SYSTEM 8Q - 3
REMOVAL AND INSTALLATION (Continued)

SLIDING DOOR AJAR (VTSS TRIGGER) SWITCH
REMOVAL
(1) Release the sliding door latch and allow back of
the door to pop open.
(2) Through opening at the rear edge of the sliding
door on outside of the vehicle, pry door ajar switch
from quarter panel opening (Fig. 7).
(3) Disconnect the wire connector from the back of
the ajar switch.
(4) Remove the sliding door ajar switch.
INSTALLATION
For installation, reverse the above procedure.
Fig. 7 Sliding Door Ajar Switch
8Q - 4 VEHICLE THEFT SECURITY SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

VEHICLE THEFT/SECURITY SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION........................ 1
SMART KEY IMMOBILIZER SYSTEM....... 1
DESCRIPTION AND OPERATION
SMART KEY IMMOBILIZER MODULE....... 1
SMART KEY IMMOBILIZER SYSTEM
INDICATOR LAMP..................... 3
SMART KEY IMMOBILIZER TRANSPONDER . 2DIAGNOSIS AND TESTING
SMART KEY IMMOBILIZER SYSTEM....... 3
SERVICE PROCEDURES
SMART KEY IMMOBILIZER SYSTEM
TRANSPONDER PROGRAMMING......... 4
REMOVAL AND INSTALLATION
SMART KEY IMMOBILIZER MODULE....... 4
GENERAL INFORMATION
INTRODUCTION
The Smart Key Immobilizer System (SKIS) is
available factory-installed optional equipment for this
model. Following are some general descriptions of the
features and components of the SKIS. Refer to the
vehicle owner's manual for more information on the
use and operation of the SKIS. Refer to 8W-30 - Fuel/
Ignition System in Group 8W - Wiring Diagrams for
complete circuit descriptions and diagrams.
SMART KEY IMMOBILIZER SYSTEM
The Smart Key Immobilizer System (SKIS) is
designed to provide passive protection against unau-
thorized vehicle use by preventing the engine from
operating while the system is armed. The primary
components of this system are the Smart Key Immo-
bilizer Module (SKIM), the Smart Key transponder,
the SKIS indicator lamp, and the Powertrain Control
Module (PCM), for gasoline engines, and the Body
Control Module (BCM) for diesel engines.
The SKIM is installed on the steering column near
the ignition lock cylinder. The transponder is located
under the molded rubber cap on the head of the igni-
tion key. The SKIS indicator lamp is located in the
instrument cluster.
The SKIS includes two valid Smart Key transpon-
ders from the factory. If the customer wishes, addi-
tional non-coded blank Smart Keys are available.
These blank keys can be cut to match a valid ignition
key, but the engine will not start unless the key tran-
sponder is also programmed to the vehicle. The SKIS
will recognize no more than eight valid Smart Key
transponders at any one time.
The SKIS performs a self-test each time the igni-
tion switch is turned to the On position, and will
store Diagnostic Trouble Codes (DTCs) if a systemmalfunction is detected. The SKIS can be diagnosed,
and any stored DTC can be retrieved using a DRB
scan tool as described in the proper Diagnostic Pro-
cedures manual.
DESCRIPTION AND OPERATION
SMART KEY IMMOBILIZER MODULE
The Smart Key Immobilizer Module (SKIM) con-
tains a Radio Frequency (RF) transceiver and a cen-
tral processing unit, which includes the Smart Key
Immobilizer System (SKIS) program logic. The SKIS
programming enables the SKIM to program and
retain in memory the codes of at least two, but no
more than eight electronically coded Smart Key tran-
sponders. The SKIS programming also enables the
SKIM to communicate over the Chrysler Collision
Detection (CCD) data bus network with the Power-
train Control Module (PCM), the instrument cluster
and/or the DRB scan tool.
The SKIM transmits and receives RF signals
through a tuned antenna enclosed within a molded
plastic ring formation that is integral to the SKIM
housing. When the SKIM is properly installed on the
steering column, the antenna ring is oriented around
the circumference of the ignition lock cylinder hous-
ing. This antenna ring must be located within eight
millimeters (0.31 inches) of the Smart Key in order
to ensure proper RF communication between the
SKIM and the Smart Key transponder.
For added system security, each SKIM is pro-
grammed with a unique ªSecret Keyº code and a
security code. The SKIM keeps the ªSecret Keyº code
in memory and sends the code over the CCD data
bus to the PCM, which also keeps this code in its
memory. The SKIM also sends the ªSecret Keyº code
to each of the programmed Smart Key transponders.
The security code is used by the assembly plant to
NS/GSVEHICLE THEFT/SECURITY SYSTEMS 8Q - 1