CHRYSLER VOYAGER 2001 Service Manual

REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the door trim panel from the appropri-
ate side door. Refer to the Body section for the pro-
cedure.
(3) Remove water shield as necessary to gain
access to motor assembly.
(4) Remove retaining clip holding flex drive assem-
bly to the motor (Fig. 8). Pull flex drive cable straight
out of the motor assembly.
(5) Disconnect door motor electrical connector.
(6) Remove the 4 screws holding the motor to the
inner door panel.
(7) Remove the motor assembly from the vehicle.
INSTALLATION
(1) Position the motor assembly on the door inner
panel.
(2) Install the 4 screws holding the motor to the
inner door panel. Torque to 35 in. lbs.
(3) Install the flex shaft by lining up the square
shaped drive shaft with corresponding hole in motor
drive unit and push straight in.
(4) Install the E-clip to secure flex-shaft.
(5) Connect the negative battery cable.
(6) Install the weather shield. Refer to the Body
section of the service manual for the procedure.(7) Install the door trim panel on the side door.
Refer to Body for the procedure.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power sliding door utilize
a full open switch. This switch is located in the hold
open latch (Fig. 9) under the side door lower hinge.
When the power side door module receives a ground
signal input from the full open switch, and as long as
the cinching latch actuator is not in power mode or
the handle switch is open, the signal indicates that
the door is at the full open position.
The full open switch is incorporated into the hold
open latch. If the full open switch proves faulty, the
entire hold open latch assembly must be replaced.
OPERATION
The full open switch is triggered by a pawl lever in
the hold open latch. When the full open switch is
closed (circuit to ground) the ratchet has engaged on
the hold open striker and the pawl lever has engaged
on the ratchet, locking the latch from opening and
holding the door in the full open position.
Fig. 8 SIDE DOOR MOTOR CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - MOTOR ASSEMBLY
Fig. 9 FULL OPEN SWITCH POSITION &
ORIENTATION
1 - HOLD OPEN LATCH ASSEMBLY
2 - HOLD OPEN LATCH CABLE
3 - FULL OPEN SWITCH
RSPOWER SLIDING DOOR SYSTEM8N-31
SLIDING DOOR MOTOR (Continued)

LEFT B-PILLAR SWITCH
DESCRIPTION
Vehicles equipped with power sliding side door/s
utilize B-pillar switches. These switches are located
on the interior of the vehicle, on the B-pillar trim
panels. These switches serve as an open and close
command switch for the appropriate power side door.
The B-pillar switches are replaceable. Consult your
Mopar parts catalog for a specific part number.
OPERATION
When the Pillar switch is depressed a signal is
sent to the Body Control Module (BCM), this signal
is then sent to the Power Sliding Door Module, tell-
ing it to start a power open or close cycle. The child
lockout feature must be disabled and the side door
must be unlocked in order for the Pillar switch to
function.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Using a trim stick or other small flat-bladed
pry tool, gently pry the leading upper edge of the
B-pillar switch away from the B-pillar trim.
(3) Once the upper edge is free from pillar trim,
rock the switch out of the switch opening.
(4) Disconnect the B-pillar switch electrical con-
nector. First, slide the connector lock away from the
switch then, depress connector retaining tab while
pulling straight apart.
(5) Remove the B-pillar switch from the vehicle.
INSTALLATION
(1) Connect the B-pillar switch electrical connector.
Slide connector lock toward the switch to lock in
place.
(2) Hook the lower edge of the B-pillar switch on
the B-pillar trim and then push the switch firmly
into position.
(3) Connect the negative battery cable.
RIGHT B-PILLAR SWITCH
DESCRIPTION
Vehicles equipped with power sliding side door/s
utilize B-pillar switches. These switches are located
on the interior of the vehicle, on the B-pillar trim
panels. These switches serve as an open and close
command switch for the appropriate power side door.
The B-pillar switches are replaceable. Consult your
Mopar parts catalog for a specific part number.
OPERATION
When the Pillar switch is depressed a signal is
sent to the Body Control Module (BCM), this signal
is then sent to the Power Sliding Door Module, tell-
ing it to start a power open or close cycle. The child
lockout feature must be disabled and the side door
must be unlocked in order for the Pillar switch to
function.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Using a trim stick or other small flat-bladed
pry tool, gently pry the leading upper edge of the
B-pillar switch away from the B-pillar trim.
(3) Once the upper edge is free from pillar trim,
rock the switch out of the switch opening.
(4) Disconnect the B-pillar switch electrical con-
nector. First, slide the connector lock away from the
switch then, depress connector retaining tab while
pulling straight apart.
(5) Remove the B-pillar switch from the vehicle.
INSTALLATION
(1) Connect the B-pillar switch electrical connector.
Slide connector lock toward the switch to lock in
place.
(2) Hook the lower edge of the B-pillar switch on
the B-pillar trim and then push the switch firmly
into position.
(3) Connect the negative battery cable.
8N - 32 POWER SLIDING DOOR SYSTEMRS

LOWER DRIVE UNIT
DESCRIPTION
Vehicles equipped with a power sliding side door
utilize a lower drive unit. The lower drive unit is
located on the sliding door lower hinge unit (Fig. 10).
This drive unit is used to transfer the lateral rotation
of the flex drive assembly into longitudinal move-
ment via the drive unit gear and door track rack
teeth (Fig. 10).
The lower drive unit is a replaceable component.
Consult your Mopar parts catalog for specific part
numbers.
OPERATION
During a power open or close cycle, the power drive
unit is driven by the flex drive assembly. The lower
drive units main gear engages the lower door tracks
rack teeth, this moves the side door assembly accord-
ingly.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Open the appropriate side door and remove the
lower drive unit cover retaining screws (Fig. 11).
(3) Remove the lower drive unit retaining fasten-
ers (Fig. 12).
Fig. 10 LOWER DRIVE UNIT
1 - LOWER DRIVE UNIT
2 - FLEX DRIVE ASSEMBLY
Fig. 11 LOWER DRIVE COVER
1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
Fig. 12 LOWER DRIVE UNIT RETAINING
FASTENERS
1 - LOWER DRIVE UNIT RETAINING SCREW
2 - DO NOT REMOVE SCREWS
3 - LOWER DRIVE UNIT RETAINING BOLT
RSPOWER SLIDING DOOR SYSTEM8N-33

(4) Disconnect the flex drive assembly from the
lower drive unit. Expand the flex drive collar until
the lower drive unit can be pulled straight off.
(5) Remove the lower drive unit from the vehicle.
INSTALLATION
(1)Position the lower drive unit near the lower hinge.
(2) Connect the flex drive assembly on the lower
drive unit. Push the flex drive collar straight on until
the it snaps in place (Fig. 12).
(3) Install the lower drive unit retaining fasteners
(Fig. 12). Torque the larger allen headed center stud
to 9 N´m (80 in. lbs.). Torque the smaller screw to 3
N´m (28 in. lbs.).
(4) Install the lower drive unit cover and retaining
screws (Fig. 11).
(5) Connect the negative battery cable.
LOWER DRIVE UNIT TRACK &
RACK
DESCRIPTION
Vehicles equipped with a power sliding side door uti-
lize a lower drive unit track or door track and rack
assembly. This track provides a mating rack gear (Fig.
13) for the lower drive unit to engage. The track also
accepts the lower hinge rollers, which helps support the
weight of the side door as well as providing a smooth
surface for the hinge rollers to move upon.
The lower door track is a replaceable component.
Consult your Mopar parts catalog for specific part
numbers.
OPERATION
With the start of a power door open cycle, the door
motor drives the flex drive assembly. The flex drive
assembly drives the lower drive unit. A powdered
metal drive gear which is part of the lower drive
unit, meshes with the door track rack teeth and
moves the door into the full open position. The same
operation repeats itself, during a power close cycle
only the system rotates in the opposite direction.
REMOVAL
(1)Disconnect and isolate the negative battery cable.
(2) Remove the side door sill plate from the lower
of the door opening. Refer to the Body section for the
procedure.
(3) Remove the hold-open striker. Refer to Body for
the procedure.
(4) Position a floor jack, with a block of wood
under the leading edge of the side door to support it
(Fig. 15).
(5) Remove the lower drive unit. Refer to the pro-
cedure in this section.
(6) Position the wire harness assembly out of door
opening (Fig. 13), this will allow the door track to be
removed easily.
(7) Pull back sealing patches (Fig. 13) and remove
the lower track retaining nuts (Fig. 14).
Fig. 13 ACCESS HOLE LOCATIONS
1 - LOWER DOOR TRACK & RACK ASSEMBLY
2 - WIRE HARNESS
3 - ACCESS HOLE SEALING PATCHES
4 - LOWER DRIVE UNIT COVER
Fig. 14 LOWER TRACK RETAINING BOLTS
1 - LOWER TRACK RETAINING BOLTS
2 - LOWER DOOR TRACK
8N - 34 POWER SLIDING DOOR SYSTEMRS
LOWER DRIVE UNIT (Continued)

(8) Carefully remove the lower door track from the
vehicle.
INSTALLATION
(1) Carefully position the lower door track in the
vehicle.
(2) Install the lower track retaining nuts (Fig. 14)
and install the sealing patches. Torque the fasteners
to 70 in. lbs.
(3) Install the lower drive unit. Refer to the proce-
dure in this section.
(4) Remove the floor jack (Fig. 15).
(5) Install the hold-open striker. Refer to the Body
section for the procedure.
(6) Install the side door sill plate on the lower of
the door opening. Refer to the Body section for the
procedure.
(7) Connect the negative battery cable.
WIRING HARNESS
DESCRIPTION
The wire harness supplies power (12v), ground and
various electrical signals to the side sliding door for
various power door functions. A plastic chain or wir-
ing track covers the wire harness assembly (Fig. 16)
and is used to protect the wire harness from abrasion
and/or tangling. This wiring track is replaced with
the wire harness assembly.
The wire harness assembly is a replaceable compo-
nent. Consult your Mopar parts catalog for specific
part numbers.
OPERATION
The wire harness and plastic wiring track provide
a safe and reliable means of supplying power, ground
and other various electrical connections to the side
sliding door. During sliding door movement the wir-
ing track folds and unfolds like the links in a chain.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate door trim panel from
the sliding side door. Refer to the Body section for
the procedure.
(3) Remove the lower drive unit cover retaining
screws and remove the cover (Fig. 17).
(4) Disconnect the power side door electrical con-
nector, located just behind the lower drive unit
assembly.
(5) Disengage retaining pushpin and pull wire har-
ness away from its power side door mounting loca-
tion (Fig. 16).
(6) Using a flat bladed screwdriver, unsnap the
wire harness retaining clip from the lower drive unit.
(7) Slide the wire harness off the forward lower
drive unit stud.
(8) Using a pushpin removal tool, unsnap wire
harness retaining pushpins from the rocker panel.
Fig. 15 SUPPORTING SIDE DOORFig. 16 WIRE HARNESS POSITION & ORIENTATION
1 - LOWER DOOR TRACK & RACK ASSEMBLY
2 - WIRE HARNESS
3 - ACCESS HOLE SEALING PATCHES
4 - LOWER DRIVE UNIT COVER
RSPOWER SLIDING DOOR SYSTEM8N-35
LOWER DRIVE UNIT TRACK & RACK (Continued)

(9) Remove side door lower sill plate. Refer to
Body for the procedure.
(10) Pull back the rearward edge of the B-pillar
trim to access the wire harness connector and discon-
nect connector.
(11) Remove the wire harness assembly from the
vehicle.
INSTALLATION
(1)Position the wire harness assembly in the vehicle.
(2) Connect the wire harness connector located at
the rearward edge of the B-pillar.
(3) Install the side door lower sill plate. Refer to
the Body section for the procedure.
(4) Snap the wire harness retaining pushpins in
the rocker panel.
(5) Slide the wire harness on the lower drive unit
stud.
(6) Install the wire harness retaining clip on the
lower drive unit stud.
(7) Connect the power side door electrical connec-
tor, located just behind the lower drive unit.
(8) Install the lower drive unit cover and retaining
screws.
(9) Install the appropriate door trim panel on the
sliding side door. Refer to the Body section for the
procedure.
(10) Connect the negative battery cable.
FLEX DRIVE
DESCRIPTION
Vehicles equipped with a power sliding side door
utilize a flex drive assembly. The flex drive assembly
is located in the lower portion of the door (Fig. 18)
and is used to connect the door motor to the lower
drive unit. An E-clip is used to secure the flexdrive to
the motor assembly, while the flex drive collar is
used to secure the drive to the lower drive unit. The
flex drive assembly is basically a flexible drive shaft
for the power side door system.
The flex drive assembly is a replaceable compo-
nent. Consult your Mopar parts catalog for specific
part numbers.
OPERATION
With one end of the flex drive attached to the door
motor and the other attached to the lower drive unit,
the flex drive transfers the power and torque from
the motor to the drive unit. A square shaped drive
cable, inside the flex drive assembly engages the
motor drive and rotates to move the door accordingly.
Fig. 17 LOWER DRIVE COVER
1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
Fig. 18 SIDE DOOR COMPONENTS
1 - SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
8N - 36 POWER SLIDING DOOR SYSTEMRS
WIRING HARNESS (Continued)

REMOVAL
(1) Disconnect and isolate the negative cable.
(2) Remove the side door trim panel from the vehi-
cle. Refer to the Body section for the procedure.
(3) Remove the weathershield. Refer to the Body
section for the procedure.
(4) Remove the E-clip from the flex drive assembly
(Fig. 19).(5) Pull the flex drive straight out of the motor
assembly.
(6) Remove the lower drive unit cover retaining
screws and remove the cover (Fig. 20).
(7) Expand the flex drive collar, next to the lower
drive unit until the flex drive can be pulled straight
off the lower drive unit.
(8)
Remove the flex drive assembly from the vehicle.
Fig. 19 SIDE DOOR MOTOR CLIP
1 - FLEX DRIVE CABLE RETAINING CLIP
2 - FLEX DRIVE CABLE
3 - MOTOR ASSEMBLY
Fig. 20 LOWER DRIVE COVER
1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
RSPOWER SLIDING DOOR SYSTEM8N-37
FLEX DRIVE (Continued)

INSTALLATION
(1) Position the flex drive assembly in the vehicle.
(2) Install the flex drive on the lower drive unit.
Push straight on until it snaps in place. It may be
necessary to rotate drive unit gear slightly until the
flex drive seats in place.
(3) Install the lower drive unit cover and retaining
screws.
(4) Install the flex drive in the motor assembly.
Line up the square shaped inner shaft and push
straight on (Fig. 21).
(5) Install the E-clip on the flex drive assembly
(Fig. 19).
(6) Install the weathershield. Refer to Body for the
procedure.
(7) Install the side door trim panel on the vehicle.
Refer to Body for the procedure.
(8) Connect the negative cable.
Fig. 21 MOTOR FLEX DRIVE CABLE
1 - DOOR MOTOR
2 - FLEX DRIVE COLLAR
3 - FLEX DRIVE INNER SHAFT
8N - 38 POWER SLIDING DOOR SYSTEMRS
FLEX DRIVE (Continued)

POWER LOCKS
TABLE OF CONTENTS
page page
POWER LOCKS
DESCRIPTION...........................39
OPERATION.............................40
DOOR LOCK MOTOR
DIAGNOSIS AND TESTING.................41
DOOR LOCK MOTOR....................41
DOOR LOCK SWITCH
DESCRIPTION...........................41
DIAGNOSIS AND TESTING.................41
DOOR LOCK SWITCH...................41
REMOVAL..............................42
INSTALLATION...........................42
KEYLESS ENTRY TRANSMITTER
STANDARD PROCEDURE..................42
HORN CHIRP PREFERENCE..............42BATTERY REPLACEMENT................42
SPECIFICATIONS........................42
REMOTE KEYLESS ENTRY MODULE
DESCRIPTION...........................43
OPERATION.............................43
DIAGNOSIS AND TESTING.................43
REMOTE KEYLESS ENTRY...............43
STANDARD PROCEDURE..................43
PROGRAMMING RKE MODULE............43
REMOVAL..............................43
INSTALLATION...........................44
SLIDING DOOR LOCK MOTOR
REMOVAL..............................44
INSTALLATION...........................44
POWER LOCKS
DESCRIPTION
POWER DOOR LOCK SYSTEM
The front doors, sliding door(s) and liftgate are
equipped with actuator motors to lock or unlock the
latch mechanisms. The door lock actuator motor is
not serviced separately from the door latch, except
for the sliding door(s).
AUTOMATIC DOOR LOCKS
The vehicle comes with two options for power door
locks:
²Rolling automatic lock (ENABLE), doors auto-
matically lock at approximately at 25.7 Km/h (16
mph).
²No rolling automatic lock (DISABLE), doors do
not automatically lock when the vehicle is moving.
DOOR LOCK INHIBIT
The BCM cancels out the door lock switch actua-
tion, when the key is in the Ignition Switch and
either front door is open.
Pressing the key fob RKE lock/unlock under these
conditions results in normal lock/unlock activation.
CENTRAL LOCKING
If equipped with Vehicle Theft Security System
(VTSS), all the doors can be locked with the key by
using any of the door lock cylinders. Turning the key
to the lock position will lock all the doors. If a sliding
door is open when this is done, the sliding door will
lock when it is closed.
DOOR LOCK CIRCUIT PROTECTION
The door lock system is protected by a 40 amp fuse
located in the IPM. The BCM receives lock/unlock
input and will turn on the appropriate drivers and
provide a voltage level to the door lock motor for a
specific time. The IPM is located along the side of the
vehicle battery in the engine compartment.
RSPOWER LOCKS8N-39

REMOTE KEYLESS ENTRY SYSTEM
The key fob transmitter (Fig. 1) has six buttons.
Three of them, LOCK, UNLOCK, and PANIC, are used
to actuate parts of, and program the Remote Keyless
Entry (RKE) system via the customer programming
mode. It is not necessary to use the PANIC button with
the DRB IIItscan tool mode of programming.
OPERATION
POWER DOOR LOCK SYSTEM
The Body Control Module (BCM) locks or unlocks the
doors when an actuation input signal from a door lock
switch or Remote Keyless Entry Module (RKE) is
received. The BCM turns on the output drivers and pro-
vides a voltage level to the door lock motor for a speci-
fied time. The BCM locks the doors and liftgate
automatically when the vehicle is driven beyond the
speed of 25.7 Km/h (15 mph). The rolling door lock fea-
ture can be disabled if desired. All doors and liftgate
can be locked or unlocked using mechanical button or
key cylinder methods (Liftgate cylinder does not lock/
unlock vehicle. It only unlocks the liftgate).
AUTOMATIC DOOR LOCKS
The BCM is equipped with a disable feature to
stop the speed sensitive automatic door locks from
functioning. The DISABLE feature can be switchedON or OFF as desired. When the system is DIS-
ABLED the door locks will operate normally, but will
not lock automatically when the vehicle is rolling.
When the door locks are ENABLED the door locks
will automatically lock when the vehicle is moving at
about 25.7 Km/h (15 mph). All doors are closed, the
PCM has set the ªOK TO LOCKº bit, and doors were
not previously locked.
DOOR LOCK INHIBIT
If the key is in the ignition, in any position, and
either front door is ajar, all power door lock function-
ing shall be disabled when activating either door lock
switch. Pressing the RKE lock/unlock button under
these conditions will result in a normal lock/unlock
activation.
After the key is removed from the Ignition Switch,
or the doors are closed, the power door locks will
operate normally.
CENTRAL LOCKING
If equipped with Vehicle Theft Security System
(VTSS), all the doors can be locked with the key by
using any of the door lock cylinders. Turning the key
to the lock position will lock all the doors. If a sliding
door is open when this is done, the sliding door will
lock when it is closed.
Holding the key in the unlock position, in any door
lock cylinder, for less than one second will unlock the
individual door for that lock cylinder. If the key is
held in the unlock position for more than one second,
all the doors will unlock.
To central unlock all doors, a second transition
from OFF to UNLOCK has to occur within 2 seconds
of the first complete UNLOCK cycle.
DOOR LOCK CIRCUIT PROTECTION
The BCM controls the door lock output drivers. If
the door lock switch is actuated continuously for
more than one second the BCM will turn the output
driver OFF (the BCM would consider the switch
stuck). The lock motors are protected with Positive
Temperature Coefficient (PTC) device that prevents
motor burn out.
REMOTE KEYLESS ENTRY SYSTEM
²LOCK: Pressing the LOCK button locks all
doors and sounds horn (chirp) and arm the Vehicle
Theft Security System. The chirp verifies that the
RKE receiver has sent a message to the BCM for
door lock operation. If a door has not been closed
before pressing the LOCK button, the vehicle may
not be secured and the VTSS will not arm until the
door is closed.
Fig. 1 KEY FOB
1 - LEFT SLIDING DOOR BUTTON
2 - RIGHT SLIDING DOOR BUTTON
3 - LIFTGATE SWITCH
8N - 40 POWER LOCKSRS
POWER LOCKS (Continued)