service indicator CHRYSLER VOYAGER 2001 Workshop Manual

OPERATION
The Compass Mini-Trip Computer (CMTC), Com-
pass Temperature (CT) module in the overhead con-
sole has buttons used to select various functions. The
CMTC, CT selector buttons will not operate until the
ignition is in the RUN position.
When the ignition switch is first turned to the
RUN position the CMTC, CT display;
²Blanks momentarily
²
All segments of the VFD will light for one second
²Blanks momentarily
²Returns to the last mode setting selected before
the ignition was last switched OFF.
DIAGNOSIS & TESTING - COMPASS MINI-TRIP
COMPUTER
Compass Mini-Trip Computer (CMTC) and Com-
pass Temperature (CT) data is obtained from the
Body Control Module (BCM) on the J1850 Data Bus
circuit. The CMTC and CT will display dashes (- -)
for any of the screens it did not receive the bus mes-
sages. The label corresponding to the missing infor-
mation will be lit. If no compass mini-trip computer
data is displayed, check the J1850 Data Bus circuit
communications and the BCM. If the brightness level
is improper check the J1850 Data Bus circuit.
The DRB IIItis recommended for checking the
J1850 Data Bus circuit and the BCM. Perform the
CMTC, CT self diagnosis before replacing the CMTC
or CT module.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove overhead console. Refer to Overhead
Console Removal and Installation in this section(Re-
fer to 8 - ELECTRICAL/OVERHEAD CONSOLE -
REMOVAL) .
(3) Remove the screws holding Compass Mini-Trip
Computer module in the overhead console.
(4) Remove CMTC module from console assembly.
INSTALLATION
(1) Position the compass mini-trip computer mod-
ule in the overhead console.
(2) Install the ten screws holding the compass
mini-trip computer module in the overhead console.
(3) Install the overhead console. Refer to Overhead
Console Removal and Installation in this section.
(4) Connect the battery negative cable.
NOTE: If a new module has been installed, the com-
pass will have to be calibrated and the variance set.
Refer to Compass Variation Adjustment and Com-
pass Calibration in the Service Procedures section
of this group for the procedures.
UNIVERSAL TRANSMITTER
DESCRIPTION
On some RS models a Homelinkttransceiver is
standard factory-installed equipment. The Homelinkt
transceiver is integral to the Electronic Vehicle Infor-
mation Center (EVIC) and the Compass Mini-Trip
Computer (CMTC), which is located in the overhead
console. The only visible component of the Homelinkt
are the three transmitter push buttons centered
between the modules push buttons located just rear-
ward of the display screen in the overhead console.
The three Homelinkttransmitter push buttons are
identified with one, two or three light indicators so
that they be easily identified by sight or by feel.
Each of the three Homelinkttransmitter push but-
tons controls an independent radio transmitter chan-
nel. Each of these three channels can be trained to
transmit a different radio frequency signal for the
remote operation of garage door openers, motorized
gate openers, home or office lighting, security sys-
tems or just about any other device that can be
equipped with a radio receiver in the 286 to 399
MegaHertz (MHz) frequency range for remote opera-
tion. The Homelinktis capable of operating systems
using either rolling code or non-rolling code technol-
ogy.
The electronics module displays messages and a
small house-shaped icon with one, two or three dots
corresponding to the three transmitter buttons to
indicate the status of the Homelinkt. The EVIC mes-
sages are:
²Cleared Channels- Indicates that all of the
transmitter codes stored in the Homelinkthave been
successfully cleared.
²Training- Indicates that the Homelinktis in
its transmitter learning mode.
²Trained- Indicates that the Homelinkthas
successfully acquired a new transmitter code.
²Transmit- Indicates that a trained Homelinkt
transmitter button has been depressed and that the
Homelinktis transmitting.
The Homelinktcannot be repaired, and is avail-
able for service only as a unit with the EVIC or
CMTC modules. If any of these components is faulty
or damaged, the complete EVIC or CMTC module
must be replaced.
OPERATION
The Homelinktoperates on a non-switched source
of battery current so the unit will remain functional,
regardless of the ignition switch position. For more
information on the features, programming procedures
and operation of the Homelinkt, see the owner's
manual in the vehicle glove box.
8M - 10 OVERHEAD CONSOLERS
COMPASS/MINI-TRIP COMPUTER (Continued)

NOTE: The VTSS will not arm by pushing down the
door lock mechanism. This will manually override
the system.
For Door Cylinder Lock Switch Removal and
Installation, refer to Electrical, Power Locks, Door
Cylinder Lock Switch.
If the VTSS is triggered, the horn will pulse, head-
lamps/marker lamps will flash, and the VTSS warn-
ing lamp will flash. If BCM determines the threat to
be false and the VTSS is not triggered again, the sys-
tem will shut down and rearm itself after three min-
utes. If a trigger is still active, the alarm will
continue for an additional 15 minutes without the
horn. The VTSS monitoring portion of the system is
split into two sections. The engine compartment sec-
tion and the passenger compartment section. If a
malfunction occurs in the engine compartment sec-
tion, the passenger compartment section would still
arm and function normally.
NOTE: If hood is not secure during the arming
sequence, the lamp will stay lit and not flash. The
system will arm with hood not secured (hood ajar
switch closed) and the liftgate open (liftgate ajar
switch closed). System will not arm if passenger
compartment is not secure (all switches closed)
ARMING THE VTSS - METHOD A
(1) With the key removed from the ignition lock
and any door open (excluding liftgate), 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. Liftgate can remain
open.
(3) After the last door is closed, an arming time-
out period of sixteen seconds will start, then the
VTSS will become armed.
ARMING THE VTSS - 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.
TRIGGERING THE VTSS
After the VTSS is armed, the following actions will
trigger the alarm:
²Opening any door.
²Opening the hood
²Turning the ignition to the ON, ACC, or
UNLOCK position.
²Opening liftgate without first receiving a RKE
input or liftgate key input.
CAUTION: The VTSS indicator LED will trigger and
engine will continue to run if the vehicle is
equipped with SKIS and the proper key is used to
start the vehicle. This condition will occur if the
VTSS has been triggered. If valid key is used, VTSS
will disarm
SENTRY KEY IMMOBILIZER SYSTEM
The SKIS includes keys from the factory which are
pre-programmed. Each SKIM will recognize a maxi-
mum of eight Sentry Keys. If the customer would
like to own additional keys other than those provided
with the vehicle, they can be purchased from any
authorized dealer. These keys must be programmed
to the SKIM on the vehicle in order for the system to
recognize them as valid keys. This can be done by
the dealer with a DRB IIItscan tool or by a cus-
tomer if this feature is available in their market and
they have two (2) valid keys already available to
them. Refer to the Service Procedures portion of this
system for additional details. The SKIS performs a
self-test each time the ignition switch is turned to
the ON position and will store Diagnostic Trouble
Codes (DTC's) if a system malfunction is detected.
The SKIS can be diagnosed and any stored DTC's
can be retrieved using a DRB IIItscan tool as
described in the appropriate Body Diagnostic Proce-
dures manual.
DIAGNOSIS AND TESTING - SENTRY KEY
IMMOBILIZER SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS,
WARNINGS, BEFORE ATTEMPTING COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
8Q - 2 VEHICLE THEFT SECURITYRS
VEHICLE THEFT SECURITY (Continued)

the OFF position. Replace the first valid Sentry Key
in the ignition lock cylinder with the second valid
Sentry Key and turn the ignition switch back to the
ON position. The second valid Sentry Key must be
inserted within 15 seconds of removing the first valid
Sentry key.
(4) About ten seconds after the completion of Step
3, the indicator light will start to flash and a single
audible chime tone will sound to indicate that the
system has entered the9Customer Learn9program-
ming mode.
(5) Within sixty seconds of entering the9Customer
Learn9programming mode, turn the ignition switch
to the OFF position, replace the valid Sentry Key
with a blank Sentry Key transponder, and turn the
ignition switch back to the ON position.
(6) About ten seconds after the completion of Step
5, a single audible chime tone will sound and the
indicator light will stop flashing and stay on solid for
three seconds and then turn off to indicate that the
blank Sentry Key has been successfully programmed.
The SKIS will immediately exit the9Customer
Learn9programming mode and the vehicle may be
started using the newly programmed Sentry Key.
These steps must be completed in their entirety for
each additional Sentry Key to be programmed. If any
of the above steps are not completed in the given
sequence, or within the allotted time, the SKIS will
exit the9Customer Learn9programming mode and
the programming will be unsuccessful. The SKIS will
also automatically exit the9Customer Learn9pro-
gramming mode if:
²It sees a non-blank Sentry Key when it should
see a blank.
²If it has already programmed eight (8) valid
Sentry Keys.
²If the ignition switch is turned to the OFF posi-
tion for more than about fifty (50) seconds.
NOTE: If you attempt to start the vehicle while in
ªCustomer Learnº mode (LED flashing), the vehicle
will behave as though an invalid key is being used
(i.e. the engine will stall after two (2) seconds of
running). No faults will be logged.
NOTE: Once a Sentry Key has been programmed to
a particular vehicle, it cannot be used on any other
vehicle.VTSS/SKIS INDICATOR LAMP
DESCRIPTION
The Sentry Key Immobilizer System (SKIS) uses
an indicator light to convey information on the status
of the system to the customer. This light is shared
with the Vehicle Theft Security System (VTSS). The
light is located in the Message Center. The indicator
light is controlled by the Body Control Module (BCM)
based upon messages it receives from the Sentry Key
Immobilizer Module (SKIM) on the PCI bus.
OPERATION
The BCM performs a four second bulb check,
regardless of SKIM messages. After the bulb check,
the lamp is controlled according to SKIM messages.
Then, the SKIM sends messages to the BCM to oper-
ate the light based upon the results of the SKIS self
tests. The light may be actuated in two possible
ways, flashing or on solid. If the light comes on and
stays on solid after a power-up test, this indicates
that the SKIM has detected a system malfunction. If
the SKIM detects an invalid key when the ignition
switch is moved to the ON position, it sends a mes-
sage on the PCI bus to the BCM, to flash the light.
The SKIM can also send a message to flash the light
and generate a single audible chime at the same
time. These two events occurring simultaneously
indicate that the SKIS has been placed into the9Cus-
tomer Learn9mode. Refer to Electrical, Vehicle Theft
Security, Transponder Key, Standard Procedure -
Transponder Programming for more information on
the9Customer Learn9mode. If the light comes on
and stays on after the power-up test, diagnosis of the
SKIS should be performed using a DRB IIItscan tool
and the appropriate Body Diagnostic Procedures
manual. The light is not a serviceable component.
RSVEHICLE THEFT SECURITY8Q-5
TRANSPONDER KEY (Continued)

²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible thecrankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Disconnect the ignition coil electrical connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer with cable adaptors to the DRBIIIt.
(7) Crank engine until maximum pressure is
reached on gage. Record this pressure as #1 cylinder
pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
9 - 78 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL SYSTEM 2.5L TURBO DIESEL
DESCRIPTION............................1
WARNING...............................1
DIAGNOSIS AND TESTING..................1
AIR IN FUEL SYSTEM....................1
FUEL SUPPLY RESTRICTIONS.............1STANDARD PROCEDURE...................2
WATER DRAINING AT FUEL FILTER.........2
CLEANING FUEL SYSTEM PARTS...........2
SPECIFICATIONS.........................2
FUEL DELIVERY..........................3
FUEL INJECTION........................10
FUEL SYSTEM 2.5L TURBO
DIESEL
DESCRIPTION - DIESEL FUEL DELIVERY
SYSTEM
The fuel system on the 2.5L Common Rail Diesel
Engine uses a fuel injection pump and an Electronic
Control Module (ECM).
The fuel delivery system consists of the:
²Accelerator pedal
²Air cleaner housing/element
²Fuel filter/water separator
²Fuel heater
²Fuel heater relay
²Fuel transfer (lift) pump
²Fuel injection pump
²Fuel injectors
²Fuel tank
²Fuel tank filler/vent tube assembly
²Fuel tank filler tube cap
²Fuel tank module containing the rollover valve
and a fuel gauge sending unit (fuel level sensor).
²Fuel tubes/lines/hoses
²High-pressure fuel injector lines
²Low-pressure fuel supply lines
²Low-pressure fuel return line
²Overflow valve
²Quick-connect fittings
²Water draining
WARNING - HIGH FUEL SYSTEM PRESSURE
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL TO EACH INDIVIDUAL INJECTOR
THROUGH HIGH-PRESSURE LINES. FUEL UNDER
THIS AMOUNT OF PRESSURE CAN PENETRATE
SKIN AND CAUSE PERSONAL INJURY. WEAR
SAFETY GOGGLES AND ADEQUATE PROTECTIVE
CLOTHING. AVOID CONTACT WITH FUEL SPRAY
WHEN BLEEDING HIGH-PRESSURE FUEL LINES.
DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM
Air will enter the fuel system whenever fuel supply
lines, separator filters, injection pump, high-pressure
lines or injectors are removed or disconnected. Air
trapped in the fuel system can result in hard start-
ing, a rough running engine, engine misfire, low
power, excessive smoke and fuel knock. After service
is performed, air must be bled from the system
before starting the engine.
Inspect the fuel system from the fuel transfer
pump to the injectors for loose connections. Leaking
fuel is an indicator of loose connections or defective
seals. Air can also enter the fuel system between the
fuel tank and the transfer pump. Inspect the fuel
tank and fuel lines for damage that might allow air
into the system.
DIAGNOSIS AND TESTING - FUEL SUPPLY
RESTRICTIONS
LOW-PRESSURE LINES
Fuel supply line restrictions or a defective fuel
transfer pump can cause starting problems and pre-
vent engine from accelerating. The starting problems
include; low power and/or white fog like exhaust.
Test all fuel supply lines for restrictions or block-
age. Flush or replace as necessary. Bleed fuel system
of air once a fuel supply line has been replaced. Refer
to Air Bleed Procedure for procedures.
To test for fuel line restrictions, a vacuum restric-
tion test may be performed. Refer to Fuel Transfer
Pump Pressure Test.
HIGH-PRESSURE LINES
Restricted (kinked or bent) high-pressure lines can
cause starting problems, poor engine performance,
engine mis-fire and white smoke from exhaust.
Examine all high-pressure lines for any damage.
Each radius on each high-pressure line must be
smooth and free of any bends or kinks.
RGFUEL SYSTEM14a-1

ASSEMBLY
NOTE: The differential is serviced as an assembly.
Service is limited to bearing cups and cones. Any
other failure must be repaired by differential assem-
bly and transfer shaft replacement.
(1) Install shim and bearing cup using Tool 5052
and driver handle C-4171 (Fig. 152). Install bearing
cup into extension housing using Tool 6536 and
driver handle C-4171.
(2) Position bearing cone onto differential (Fig.
153), and install bearing cone using Tool 6536 and
driver handle C-4171 (Fig. 154).(3) Measure side gear end play using dial indicator
C-3339 and Tool C-4996 (Fig. 155) (Fig. 156).Side
gear end play must be between 0.001 and 0.013
in.
(4) Apply a bead of Moparž Silicone Rubber Adhe-
sive Sealant to the adapter plate. Load differential
assembly into position and install adapter plate .
(5) Using Tool L-4435, index adapter plate until
bolt holes align.
(6) Install adapter plate-to-transaxle case bolts
and torque to 28 N´m (250 in. lbs.) torque.
Fig. 152 Bearing Retainer Bearing Cup Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5052
3 - DIFFERENTIAL BEARING RETAINER
Fig. 153 Position Bearing Cone Onto Differential
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL BEARING
Fig. 154 Install Differential Bearing Cone
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 6536
3 - DIFFERENTIAL ASSEMBLY
Fig. 155 Checking Side Gear End Play
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
21 - 94 AUTOMATIC - 31THRS
FINAL DRIVE (Continued)

FLUID
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
FLUID LEVEL CHECK
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion.The fluid should be at normal operating
temperature (approximately 82 C. or 180 F.). The
fluid level is correct if it is in the HOT region (cross-
hatched area) on the fluid level indicator (Fig. 165).
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from the
transaxle dipstick where it may be mistaken for a
leak.Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is needed.
Be sure to examine the fluid on the dipstick closely.
If there is any doubt about its condition, drain out a
sample for a double check.
Moparž ATF+4 (Automatic Transmission Fluid-
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown. This is normal. A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
CHANGE
NOTE: For the recommended maintenance (fluid/fil-
ter change) intervals for this transaxle, (Refer to
LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
NOTE: Only fluids of the type labeled Moparž
ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Place a drain con-
tainer with a large opening, under transaxle oil pan.
Fig. 165 Fluid Level Indicator Markings
1 - TRANSAXLE DIPSTICK
21 - 98 AUTOMATIC - 31THRS

(4) Remove fluid level indicator/tube assembly.
Plug opening to prevent debris from entering trans-
axle.
(5) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly.
(6) Disconnect input and output shaft speed sensor
connectors (Fig. 10).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 10).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 10).
(9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 11).
(10) Disconnect crankshaft position sensor (if
equipped).
(11) Reposition leak detection pump harness and
hoses.
(12) Remove wiper module assembly to gain access
to and remove rear mount bracket bolts. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL)
(13) Remove rear mount bracket-to-transaxle case
bolts (Fig. 12).
(14) Remove transaxle upper bellhousing-to-block
bolts.
(15) Raise vehicle on hoist.
(16) Remove transaxle oil pan and drain fluid into
suitable container.
(17) Remove front wheel/tire assemblies.
Fig. 9 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY/RESERVE CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
Fig. 10 Component Connector LocationÐTypical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 11 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 166 AUTOMATIC - 41TERS
AUTOMATIC - 41TE (Continued)

INSTALLATION
NOTE: If transaxle assembly has been replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perfrom the TCM Quick Learn proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
NOTE: If torque converter assembly has been
replaced, it is necessary to reset the TCC Break-In
Strategy. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) Using a transmission jack and a helper, posi-
tion transaxle assembly to engine. Install and torque
bolts to 95 N´m (70 ft. lbs.).
(2) Install upper mount assembly to transaxle and
torque bolts to 54 N´m (40 ft. lbs.) (Fig. 164).
(3) Raise engine/transaxle assembly into position.
Install and torque upper mount-to-bracket thru-bolt
to 75 N´m (55 ft. lbs.) (Fig. 164).
(4) Remove transmission jack and screw jack.
(5) Secure left wheelhouse splash shield.
(6) Install torque converter-to-drive plate bolts and
torque to 88 N´m (65 ft. lbs.)
(7) Install inspection cover.(8) Install lateral bending brace.
(9) Install starter motor.
(10) Install front mount/bracket assembly.
(11) Install rear mount and bracket assembly into
position (Fig. 165).
(12) Install and torque rear mount bolts to 54 N´m
(40 ft. lbs.) (Fig. 166).
(13) Lower vehicle.
(14) Install and torque rear mount bracket-to-tran-
saxle vertical bolts (Fig. 165) to 102 N´m (75 ft. lbs.).
(15) Raise vehicle.
(16) Install rear mount bracket-to-transaxle hori-
zontal bolt (Fig. 165) and torque to 102 N´m (75 ft.
lbs.).
(17) Install rear mount thru-bolt and torque to 54
N´m (40 ft. lbs.) (Fig. 166).
(18) Install rear mount heat shield (Fig. 167).
(19) AWD models: Install power transfer unit.
(Refer to 21 - TRANSMISSION/TRANSAXLE/
POWER TRANSFER UNIT - INSTALLATION)
(20) Install cradle plate.
(21) Install exhaust pipe to manifold (Fig. 168).
(22) Install left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - INSTALLATION)
(23) Install front wheel/tire assemblies.
(24) Lower vehicle.
(25) Install transaxle upper bellhousing-to-block
bolts and torque to 95 N´m (70 ft. lbs.).
(26) Install wiper module assembly. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION)
(27) Connect crank position sensor (if equipped).
(28) Connect gearshift cable to upper mount
bracket and transaxle manual valve lever (Fig. 169).
(29) Connect solenoid/pressure switch assembly
(Fig. 170).
(30) Connect transmission range sensor connector
(Fig. 170).
(31) Connect input and output speed sensor con-
nectors (Fig. 170).
(32) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit.
(33) Remove plug and Install fluid level indicator/
tube assembly.
(34) Install coolant recovery bottle (Fig. 171).
(35) Install battery shield.
(36) Connect battery cables.
(37) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 164 Left Mount to Bracket and Transaxle
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
RSAUTOMATIC - 41TE21 - 209
AUTOMATIC - 41TE (Continued)

OPERATION
The function of an accumulator is to cushion the
application of a frictional clutch element. When pres-
surized fluid is applied to a clutch circuit, the appli-
cation force is dampened by fluid collecting in the
respective accumulator chamber against the piston
and spring(s). The intended result is a smooth, firm
clutch application.
AUTOSTICK SWITCH
DESCRIPTION
Autostick is a driver-interactive transaxle feature
that offers manual gear shifting capability. The con-
trol switch is part of the transaxle gear shift lever as
shown in (Fig. 175). It can only be serviced by replac-
ing the gearshift lever assembly. (Refer to 19 -
STEERING/COLUMN/GEAR SHIFT LEVER -
REMOVAL)
OPERATION
When the shift lever is moved into the Autostick
position (as indicated by the Shift Lever Position
Indicator in the cluster), the transaxle remains in
whatever gear it was using before Autostick was acti-
vated. The TCM sends a 5 volt signal through the
switch and then monitors the signal for voltage drop.
Each switch state (driver command) results in a spe-
cific voltage reading sensed by the TCM. The TCM
then determines transaxle operation (upshift/down-
shift/OD Lockout) based on their corresponding volt-
age. Refer to the following chart for corresponding
switch states and voltage readings:
Switch State Voltage Reading
Autostick DOWN
depressed0.3V-1.6V
Autostick UP depressed 1.6V-2.8V
Overdrive OFF9Lockout9
depressed2.8V-3.8V
All switches open 3.8V-4.8V
-Voltage values <.3V and >4.8V are considered
INVALID and will result in a DTC
Moving the switch up causes an upshift and mov-
ing the switch down causes a downshift. The instru-
ment cluster will illuminate the selected gear. The
vehicle can be launched in 1st, 2nd, or 3rd gear while
in the Autostick mode. The speed control is operable
Fig. 173 Low/Reverse Accumulator Assembly
1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
Fig. 174 2/4 Accumulator Assembly
1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - SPRINGS
5 - SEALS
6 - PISTON
Fig. 175 Autostick Switch Location (if equipped)
RSAUTOMATIC - 41TE21 - 233
ACCUMULATOR (Continued)