park assist CHRYSLER VOYAGER 2002 Service Manual

Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
Over 40 auto manufacturers world-wide have
issued and endorsed consistent gasoline specifications
(the Worldwide Fuel Charter, WWFC) to define fuel
properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We rec-
ommend the use of gasolines that meet the WWFC
specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as ªreformulat-
edº gasoline. Reformulated gasoline contain oxygen-
ates, and are specifically blended to reduce vehicle
emissions and improve air quality.
We strongly support the use of reformulated gaso-
line. Properly blended reformulated gasoline will pro-
vide excellent performance and durability for the
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasoline free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gaso-
line retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline with-
out MMT in Canada because MMT can be used atlevels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with Cleaner-Burning Cali-
fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
emission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission control system performance may be
adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle's catalytic con-
verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a dif-
ferent brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle's performance:
²The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could result in loss of warranty coverage.
²An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
²When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
RSLUBRICATION & MAINTENANCE0-5
FLUID TYPES (Continued)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
SCRAPING (METAL-TO-
METAL).1. Foreign object interference with
brakes.1. Inspect brakes and remove foreign
object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and
drums. Reface or replace as necessary.
OTHER BRAKE CONDITIONS
CONDITION POSSIBLE CAUSES CORRECTION
BRAKES CHATTER 1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
BRAKES DRAG (FRONT
OR ALL)1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings.
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
5. Brake lamp switch not adjusted
properly and mounting bracket is
bent.5. Straighten mounting bracket and
replace brake lamp switch.
BRAKES DRAG (REAR
ONLY)1. Parking brake cables binding or
froze up.1. Check cable routing. Replace cables
as necessary.
2. Parking brake cable return spring
not returning shoes.2. Replace cables as necessary.
3. Service brakes not adjusted
properly (rear drum brakes only).3. Follow the procedure listed in the
adjustment section.
4. Rear disc brake parking brake not
properly adjusted.Adjust parking brake shoes.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Improper power brake booster
assist.2. Refer to power brake booster
diagnosis and testing.
EXCESSIVE PEDAL
EFFORT1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.
2. Low power brake booster assist
(vacuum leak).2. Refer to power brake booster
diagnosis and testing.
3. Glazed brake linings. 3. Reface or replace brake rotors as
necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake
rotor.4. Reface or replace brake rotors as
necessary. Replace brake shoes.
EXCESSIVE PEDAL
TRAVEL (VEHICLE STOPS
OK)1. Air in brake lines. 1. Bleed brakes.
2. Rear drum brake auto-adjuster
malfunctioning.2. Inspect and replace drum brake
components as necessary. Adjust rear
brakes.
5 - 6 BRAKES - BASERS
BRAKES - BASE (Continued)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE PEDAL
TRAVEL (ONE FRONT
WHEEL LOCKS UP
DURING HARD BRAKING)1. One of the two hydraulic circuits
to the front brakes is malfunctioning.1. Inspect system for leaks. Check
master cylinder for internal malfunction.
PEDAL PULSATES/
SURGES DURING
BRAKING1. Rear brake drum out of round or
disc brake rotor has excessive
thickness variation.1. Isolate condition as rear or front.
Reface or replace brake drums or
rotors as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.
2. Power brake booster runout
(vacuum assist).2. Check booster vacuum hose and
engine tune for adequate vacuum
supply. Refer to power brake booster
diagnosis and testing.
PREMATURE REAR
WHEEL LOCKUP1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Inoperative proportioning valve
(non-ABS vehicles).2. Refer to proportioning valve
diagnosis and testing. Replace valve as
necessary.
3. Improper power brake booster
assist.3. Refer to power brake booster in the
diagnosis and testing section.
STOP/BRAKE LAMPS
S TAY O N1. Brake lamp switch out of
adjustment.1. Replace brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing
pedal to return completely.4. Replace power brake booster.
VEHICLE PULLS TO
RIGHT OR LEFT ON
BRAKING1. Frozen brake caliper piston. 1. Replace frozen piston or caliper.
Bleed brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE -
EXCESSIVE HANDLE
TRAVEL1. Rear drum brakes or rear disc
brake parking brake shoes out of
adjustment.1. Adjust rear drum brake shoes, or
rear parking brake shoes on vehicles
with rear disc brakes.
STANDARD PROCEDURE - BASE BRAKE
BLEEDING
NOTE: This bleeding procedure is only for the vehi-
cle's base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, (Refer to 5 -
BRAKES - ABS - STANDARD PROCEDURE)CAUTION: Before removing the master cylinder
cover, thoroughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
RSBRAKES - BASE5-7
BRAKES - BASE (Continued)
ProCarManuals.com

electrolyte can be caused by an overcharging condi-
tion. Be certain to diagnose the charging system after
replenishing the water in the battery for a low elec-
trolyte condition and before returning the vehicle to
service. Refer toCharging Systemfor additional
information.
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity
(RC) rating or Ampere-Hours (AH) rating can be
found on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Refer to
Battery Specificationsin this group for the loca-
tion of the proper factory-installed battery specifica-
tions.
OPERATION
The battery is designed to store electrical energy in
a chemical form. When an electrical load is applied to
the terminals of the battery, an electrochemical reac-
tion occurs. This reaction causes the battery to dis-
charge electrical current from its terminals. As the
battery discharges, a gradual chemical change takes
place within each cell. The sulfuric acid in the elec-
trolyte combines with the plate materials, causing
both plates to slowly change to lead sulfate. At the
same time, oxygen from the positive plate material
combines with hydrogen from the sulfuric acid, caus-
ing the electrolyte to become mainly water. The
chemical changes within the battery are caused by
the movement of excess or free electrons between the
positive and negative plate groups. This movement of
electrons produces a flow of electrical current
through the load device attached to the battery ter-
minals.
As the plate materials become more similar chem-
ically, and the electrolyte becomes less acid, the volt-
age potential of each cell is reduced. However, by
charging the battery with a voltage higher than that
of the battery itself, the battery discharging process
is reversed. Charging the battery gradually changes
the sulfated lead plates back into sponge lead and
lead dioxide, and the water back into sulfuric acid.
This action restores the difference in the electron
charges deposited on the plates, and the voltage
potential of the battery cells. For a battery to remain
useful, it must be able to produce high-amperage cur-
rent over an extended period. A battery must also be
able to accept a charge, so that its voltage potential
may be restored.
The battery is vented to release excess hydrogen
gas that is created when the battery is being charged
or discharged. However, even with these vents,
hydrogen gas can collect in or around the battery. Ifhydrogen gas is exposed to flame or sparks, it may
ignite. If the electrolyte level is low, the battery may
arc internally and explode. If the battery is equipped
with removable cell caps, add distilled water when-
ever the electrolyte level is below the top of the
plates. If the battery cell caps cannot be removed, the
battery must be replaced if the electrolyte level
becomes low.
DIAGNOSIS AND TESTING - BATTERY
The battery must be completely charged and the
terminals should be properly cleaned and inspected
before diagnostic procedures are performed. Refer to
Battery System Cleaning for the proper cleaning pro-
cedures, and Battery System Inspection for the
proper battery inspection procedures. Refer to Stan-
dard Procedures for the proper battery charging pro-
cedures.
MICRO 420 ELECTRICAL SYSTEM TESTER
The Micro420 automotive battery tester is designed
to help the dealership technicians diagnose the cause
of a defective battery. Follow the instruction manual
supplied with the tester to properly diagnose a vehi-
cle. If the instruction manual is not available refer to
the standard procedure in this section, which
includes the directions for using the Micro420 electri-
cal system tester.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
A battery that will not accept a charge is faulty,
and must be replaced. Further testing is not
required. A fully-charged battery must be load tested
to determine its cranking capacity. A battery that is
fully-charged, but does not pass the load test, is
faulty and must be replaced.
RSBATTERY SYSTEM8F-9
BATTERY (Continued)
ProCarManuals.com

CHARGE RATE TABLE
Voltage Hours
14.4 volts maximum up to 4 hours
13.0 to 14 volts up to 8 hours
12.9 volts or less up to 16 hours
CHARGING TIME REQUIRED
The time required to charge a battery will vary,
depending upon the following factors:
²Battery Capacity- A completely discharged
heavy-duty battery requires twice the charging time
of a small capacity battery.
²Temperature- A longer time will be needed to
charge a battery at -18É C (0É F) than at 27É C (80É
F). When a fast battery charger is connected to a cold
battery, the current accepted by the battery will be
very low at first. As the battery warms, it will accept
a higher charging current rate (amperage).
²Charger Capacity- A battery charger that
supplies only five amperes will require a longer
charging time. A battery charger that supplies eight
amperes will require a shorter charging time.
²State-Of-Charge- A completely discharged bat-
tery requires more charging time than a partially
discharged battery. Electrolyte is nearly pure water
in a completely discharged battery. At first, the
charging current (amperage) will be low. As the bat-
tery charges, the specific gravity of the electrolyte
will gradually rise.
The Battery Charging Time Table gives an indica-
tion of the time required to charge a typical battery
at room temperature based upon the battery state-of-
charge and the charger capacity.
BATTERY CHARGING TIME TABLE
Charging
Amperage5 Amps 8 Amps
Open Circuit
VoltageHours Charging @ 21É
C (70É F)
12.25 to 12.49 6 hours 3 hours
12.00 to 12.24 10 hours 5 hours
10.00 to 11.99 14 hours 7 hours
Below 10.00 18 hours 9 hours
STANDARD PROCEDURE - CONVENTIONAL
BATTERY CHARGING
Vehicles equipped with a diesel engine utilize a
unique spiral plate battery. This battery has a maxi-
mum charging voltage that must be used in order to
restore the battery to its full potential, failure to use
the spiral plate battery charging procedure could
result in damage to the battery or personal injury.Battery charging is the means by which the bat-
tery can be restored to its full voltage potential. A
battery is fully-charged when:
²Micro 420 electrical system tester indicates bat-
tery is OK.
²Three hydrometer tests, taken at one-hour inter-
vals, indicate no increase in the temperature-cor-
rected specific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.64 volts
or above.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING, LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS IS IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
RSBATTERY SYSTEM8F-11
BATTERY (Continued)
ProCarManuals.com

tive plates to prevent them from contacting or short-
ing against one another. These dissimilar metal
plates are submerged in a sulfuric acid and water
solution called an electrolyte.
Some factory-installed batteries have a built-in test
indicator (hydrometer). The color visible in the sight
glass of the indicator will reveal the battery condi-
tion. For more information on the use of the built-in
test indicator, refer toStandard ProceduresThe
chemical composition of the metal coated plates
within the low-maintenance battery reduces battery
gassing and water loss, at normal charge and dis-
charge rates. Therefore, the battery should not
require additional water in normal service. If the
electrolyte level in this battery does become low, dis-
tilled water must be added. However, rapid loss of
electrolyte can be caused by an overcharging condi-
tion. Be certain to diagnose the charging system after
replenishing the water in the battery for a low elec-
trolyte condition and before returning the vehicle to
service. Refer toCharging Systemfor additional
information.
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity
(RC) rating or Ampere-Hours (AH) rating can be
found on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Refer to
Battery Specificationsin this group for the loca-
tion of the proper factory-installed battery specifica-
tions.
OPERATION
The battery is designed to store electrical energy in
a chemical form. When an electrical load is applied to
the terminals of the battery, an electrochemical reac-
tion occurs. This reaction causes the battery to dis-
charge electrical current from its terminals. As the
battery discharges, a gradual chemical change takes
place within each cell. The sulfuric acid in the elec-
trolyte combines with the plate materials, causing
both plates to slowly change to lead sulfate. At the
same time, oxygen from the positive plate material
combines with hydrogen from the sulfuric acid, caus-
ing the electrolyte to become mainly water. The
chemical changes within the battery are caused by
the movement of excess or free electrons between the
positive and negative plate groups. This movement of
electrons produces a flow of electrical current
through the load device attached to the battery ter-
minals.
As the plate materials become more similar chem-
ically, and the electrolyte becomes less acid, the volt-
age potential of each cell is reduced. However, bycharging the battery with a voltage higher than that
of the battery itself, the battery discharging process
is reversed. Charging the battery gradually changes
the sulfated lead plates back into sponge lead and
lead dioxide, and the water back into sulfuric acid.
This action restores the difference in the electron
charges deposited on the plates, and the voltage
potential of the battery cells. For a battery to remain
useful, it must be able to produce high-amperage cur-
rent over an extended period. A battery must also be
able to accept a charge, so that its voltage potential
may be restored.
The battery is vented to release excess hydrogen
gas that is created when the battery is being charged
or discharged. However, even with these vents,
hydrogen gas can collect in or around the battery. If
hydrogen gas is exposed to flame or sparks, it may
ignite. If the electrolyte level is low, the battery may
arc internally and explode. If the battery is equipped
with removable cell caps, add distilled water when-
ever the electrolyte level is below the top of the
plates. If the battery cell caps cannot be removed, the
battery must be replaced if the electrolyte level
becomes low.
DIAGNOSIS AND TESTING - BATTERY
The battery must be completely charged and the
terminals should be properly cleaned and inspected
before diagnostic procedures are performed. Refer to
Battery System Cleaning for the proper cleaning pro-
cedures, and Battery System Inspection for the
proper battery inspection procedures. Refer to Stan-
dard Procedures for the proper battery charging pro-
cedures.
MICRO 420 ELECTRICAL SYSTEM TESTER
The Micro420 automotive battery tester is designed
to help the dealership technicians diagnose the cause
of a defective battery. Follow the instruction manual
supplied with the tester to properly diagnose a vehi-
cle. If the instruction manual is not available refer to
the standard procedure in this section, which
includes the directions for using the Micro420 electri-
cal system tester.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
RGBATTERY SYSTEM8Fa-9
BATTERY (Continued)
ProCarManuals.com

turer of the battery charger for details on how to
bypass the polarity-sensing circuitry.
(3) Battery chargers vary in the amount of voltage
and current they provide. The amount of time
required for a battery to accept measurable charging
current at various voltages is shown in the Charge
Rate Table. If the charging current is still not mea-
surable at the end of the charging time, the battery
is faulty and must be replaced. If the charging cur-
rent is measurable during the charging time, the bat-
tery may be good and the charging should be
completed in the normal manner.
CHARGE RATE TABLE
Voltage Hours
14.4 volts maximum up to 4 hours
13.0 to 14 volts up to 8 hours
12.9 volts or less up to 16 hours
CHARGING TIME REQUIRED
The time required to charge a battery will vary,
depending upon the following factors:
²Battery Capacity- A completely discharged
heavy-duty battery requires twice the charging time
of a small capacity battery.
²Temperature- A longer time will be needed to
charge a battery at -18É C (0É F) than at 27É C (80É
F). When a fast battery charger is connected to a cold
battery, the current accepted by the battery will be
very low at first. As the battery warms, it will accept
a higher charging current rate (amperage).
²Charger Capacity- A battery charger that
supplies only five amperes will require a longer
charging time. A battery charger that supplies eight
amperes will require a shorter charging time.
²State-Of-Charge- A completely discharged bat-
tery requires more charging time than a partially
discharged battery. Electrolyte is nearly pure water
in a completely discharged battery. At first, the
charging current (amperage) will be low. As the bat-
tery charges, the specific gravity of the electrolyte
will gradually rise.
The Battery Charging Time Table gives an indica-
tion of the time required to charge a typical battery
at room temperature based upon the battery state-of-
charge and the charger capacity.
BATTERY CHARGING TIME TABLE
Charging
Amperage5 Amps 8 Amps
Open Circuit
VoltageHours Charging @ 21É
C (70É F)
12.25 to 12.49 6 hours 3 hours
12.00 to 12.24 10 hours 5 hours
10.00 to 11.99 14 hours 7 hours
Below 10.00 18 hours 9 hours
STANDARD PROCEDURE - CONVENTIONAL
BATTERY CHARGING
Vehicles equipped with a diesel engine utilize a
unique spiral plate battery. This battery has a maxi-
mum charging voltage that must be used in order to
restore the battery to its full potential, failure to use
the spiral plate battery charging procedure could
result in damage to the battery or personal injury.
Battery charging is the means by which the bat-
tery can be restored to its full voltage potential. A
battery is fully-charged when:
²Micro 420 electrical system tester indicates bat-
tery is OK.
²Three hydrometer tests, taken at one-hour inter-
vals, indicate no increase in the temperature-cor-
rected specific gravity of the battery electrolyte.
²Open-circuit voltage of the battery is 12.64 volts
or above.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING, LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
RGBATTERY SYSTEM8Fa-11
BATTERY (Continued)
ProCarManuals.com

8W-15 GROUND DISTRIBUTION
Component PageA/C Compressor Clutch...................8W-15-7, 8
A/C- Heater Control....................8W-15-9, 11
Adjustable Pedals Module..................8W-15-17
Airbag Control Module....................8W-15-12
Auto Temp Control.......................8W-15-9
Automatic Day/Night Mirror.................8W-15-21
Autostick Switch........................8W-15-10
Back-Up Lamp Switch....................8W-15-3, 7
Battery.............................8W-15-2, 3
Body Control Module.....................8W-15-22
Brake Fluid Level Switch...................8W-15-17
Brake Lamp Switch......................8W-15-17
Cabin Heater Assist.......................8W-15-8
Center Dome Lamp......................8W-15-21
Center High Mounted Stop Lamp..............8W-15-26
Clutch Pedal Upstop Switch.................8W-15-18
Controller Antilock Brake..................8W-15-2, 3
Crank Case Ventilation Heater................8W-15-8
Crankshaft Position Sensor..................8W-15-3
Data Link Connector..................8W-15-2, 3, 17
Dosing Pump...........................8W-15-8
Driver Door Courtesy Lamp...............8W-15-15, 20
Driver Door Lock Switch.................8W-15-15, 20
Driver Heated Seat Cushion.................8W-15-11
Driver Heated Seat Module.................8W-15-11
Driver Power Seat Switch..................8W-15-11
Driver Power Window Switch..............8W-15-15, 20
Engine Control Module.....................8W-15-3
Floor Console Lamp......................8W-15-25
Floor Console Power Outlet.................8W-15-25
Front Blower Module.....................8W-15-11
Front Cigar Lighter.......................8W-15-9
Front Control Module..................8W-15-7, 8, 18
Front Reading Lamps/Switch................8W-15-21
Fuel Heater...........................8W-15-25
Fuel Heater Relay........................8W-15-3
Fuel Pump Module.......................8W-15-25
G100..............................8W-15-2, 3
G101..............................8W-15-2, 3
G102.............................8W-15-4, 5, 6
G103..............................8W-15-7, 8
G200...........................8W-15-9, 10, 11
G201...............................8W-15-12
G202...............................8W-15-13
G300........................8W-15-14, 16, 17, 18
G301........................8W-15-19, 20, 21, 22
G302...........................8W-15-23, 24, 25
G400.............................8W-15-25, 26
Glove Box Lamp........................8W-15-10
Halo Lamp............................8W-15-10
Headlamp Switch........................8W-15-9
Headlamp Washer Pump Motor................8W-15-6
High Note Horn........................8W-15-5, 6
Hood Ajar Switch........................8W-15-18
Instrument Cluster.......................8W-15-9
Instrument Panel Switch Bank...............8W-15-10
Integrated Power Module............8W-15-2, 3, 7, 8, 18
Left B-Pillar Switch......................8W-15-17
Left Cinch/Release Motor...................8W-15-14
Left Combination Relay....................8W-15-24
Left Cylinder Lock Switch................8W-15-15, 16
Left Door Speaker.......................8W-15-13
Left Fog Lamp........................8W-15-5, 6
Left Front Door Ajar Switch.................8W-15-16
Left Front Door Lock Motor/Ajar Switch.......8W-15-15, 16
Left Front Park/Turn Signal Lamp..............8W-15-5
Left Full Open Switch.....................8W-15-14
Left Headlamp.........................8W-15-18
Left Headlamp Leveling Motor................8W-15-6
Left High Beam Lamp....................8W-15-18
Left Liftgate Flood Lamp...................8W-15-26
Left Low Beam Lamp.....................8W-15-18
Left Mid Reading Lamp....................8W-15-21
Left Park Lamp.........................8W-15-18
Left Power Mirror.......................8W-15-10
Left Rear Lamp Assembly..................8W-15-24
Left Rear Reading Lamp...................8W-15-21
Left Side Impact Airbag Control Module.........8W-15-12
Left Sliding Door Control Module..............8W-15-14
Left Sliding Door Latch Sensing Switch..........8W-15-14
Left Sliding Door Lock Motor................8W-15-14Component PageLeft Sliding Door Lock Motor/Ajar Switch.........8W-15-14
Left Sliding Door Motor....................8W-15-14
Left Stop/Turn Signal Relay.................8W-15-24
Left Turn Signal Lamp....................8W-15-18
Left Visor/Vanity Lamp....................8W-15-21
License Lamp........................8W-15-23, 26
Lift Pump Motor........................8W-15-25
Liftgate Ajar Switch......................8W-15-26
Liftgate Cinch/Release Motor................8W-15-23
Liftgate Cylinder Lock Switch................8W-15-26
Liftgate Right Pinch Sensor.................8W-15-23
Low Note Horn........................8W-15-5, 6
Memory Seat/Mirror Module.................8W-15-11
Overhead Console.......................8W-15-21
Oxygen Sensor 1/2 Downstream...............8W-15-7
Park/Neutral Position Switch.................8W-15-7
Passenger Door Courtesy Lamp............8W-15-16, 20
Passenger Door Lock Switch..............8W-15-16, 20
Passenger Heated Seat Module...............8W-15-22
Passenger Power Seat Switch................8W-15-22
Passenger Power Window Switch............8W-15-16, 20
Power Folding Mirror Switch................8W-15-11
Power Liftgate Module....................8W-15-23
Power Liftgate Motor.....................8W-15-23
Power Mirror Switch......................8W-15-11
Power Outlet...........................8W-15-9
Power Window Switch.....................8W-15-15
Powertrain Control Module..................8W-15-2
Radiator Fan No. 1.......................8W-15-4
Radiator Fan No. 2.......................8W-15-4
Radiator Fan Relay.......................8W-15-4
Radiator Fan Relay No. 3...................8W-15-4
Radio...............................8W-15-13
Rear Auto Temp Control Switch...............8W-15-17
Rear Blower Front Control Switch.............8W-15-11
Rear Blower Motor Power Module...........8W-15-11, 25
Rear Blower Rear Control Switch..............8W-15-17
Rear Dome Lamp........................8W-15-21
Rear Power Outlet.......................8W-15-25
Rear Window Defogger Grid.................8W-15-26
Rear Wiper Motor.......................8W-15-26
Remote Keyless Entry Module................8W-15-10
Right B-Pillar Switch.....................8W-15-22
Right Cinch/Release Motor..................8W-15-19
Right Combination Relay...................8W-15-24
Right Cylinder Lock Switch.................8W-15-20
Right Door Speaker......................8W-15-13
Right Fog Lamp........................8W-15-5, 6
Right Front Door Ajar Switch................8W-15-20
Right Front Door Lock Motor/Ajar Switch.........8W-15-20
Right Front Park/Turn Signal Lamp.............8W-15-5
Right Full Open Switch....................8W-15-19
Right Headlamp........................8W-15-18
Right Headlamp Leveling Motor...............8W-15-6
Right High Beam Lamp....................8W-15-18
Right Liftgate Flood Lamp..................8W-15-26
Right Low Beam Lamp....................8W-15-18
Right Mid Reading Lamp...................8W-15-21
Right Park Lamp........................8W-15-18
Right Power Mirror......................8W-15-10
Right Rear Lamp Assembly.................8W-15-25
Right Rear Reading Lamp..................8W-15-21
Right Side Impact Airbag Control Module.........8W-15-12
Right Sliding Door Control Module.............8W-15-19
Right Sliding Door Latch Sensing Switch.........8W-15-19
Right Sliding Door Lock Motor...............8W-15-19
Right Sliding Door Lock Motor/Ajar Switch........8W-15-19
Right Sliding Door Motor...................8W-15-19
Right Stop/Turn Signal Relay................8W-15-24
Right Turn Signal Lamp...................8W-15-18
Right Visor/Vanity Lamp...................8W-15-21
Sentry Key Immobilizer Module...............8W-15-10
Speed Control Servo.......................8W-15-7
Traction Control Switch....................8W-15-10
Trailer Tow Connector.....................8W-15-24
Transmission Control Module.................8W-15-2
Transmission Control Relay..................8W-15-2
Transmission Range Sensor..................8W-15-7
Washer Fluid Level Switch.................8W-15-5, 6
Wiper Module..........................8W-15-17
RS8W-15 GROUND DISTRIBUTION8W-15-1
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8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch............... 8W-30-18
A/C Compressor Clutch Relay........ 8W-30-3, 18
A/C Pressure Sensor............ 8W-30-9, 15, 25
Accelerator Pedal Position Sensor....... 8W-30-32
Adjustable Pedals Module............. 8W-30-17
Adjustable Pedals Switch............. 8W-30-17
Auto Shut Down Relay.... 8W-30-2, 5, 7, 8, 12, 13
Battery...................... 8W-30-2, 18, 26
Battery Temperature Sensor........... 8W-30-25
Body Control Module.............. 8W-30-4, 19
Boost Pressure Sensor................ 8W-30-25
Brake Lamp Switch............. 8W-30-6, 21, 31
Cabin Heater Assist................. 8W-30-22
Camshaft Position Sensor........ 8W-30-7, 13, 24
Clockspring...................... 8W-30-3, 23
Clutch Pedal Upstop Switch........... 8W-30-30
Crank Case Ventilation Heater......... 8W-30-19
Crankshaft Position Sensor....... 8W-30-7, 13, 24
Data Link Connector............... 8W-30-4, 22
Diagnostic Junction Port......... 8W-30-4, 23, 17
Dosing Pump....................... 8W-30-22
ECM/PCM Relay........ 8W-30-18, 20, 24, 26, 28
EGR Solenoid.................... 8W-30-5, 28
Engine Control Module . . . 8W-30-18, 19, 20, 21, 22,
23, 24, 25, 26, 27, 28, 29, 30, 31, 32
Engine Coolant Temp Sensor...... 8W-30-9, 15, 25
Engine Oil Pressure Sensor........... 8W-30-21
Engine Oil Pressure Switch............ 8W-30-6
Engine Oil Temperature Sensor........ 8W-30-24
Evap/Purge Solenoid.................. 8W-30-3
Front Control Module...... 8W-30-3, 4, 17, 22, 30
Fuel Heater........................ 8W-30-29
Fuel Heater Relay................ 8W-30-19, 29
Fuel Injector No. 1............. 8W-30-8, 12, 27
Fuel Injector No. 2............. 8W-30-8, 12, 27
Fuel Injector No. 3............. 8W-30-8, 12, 27
Fuel Injector No. 4............. 8W-30-8, 12, 27
Fuel Injector No. 5.................. 8W-30-12
Fuel Injector No. 6.................. 8W-30-12
Fuel Pressure Sensor................ 8W-30-31
Fuel Pressure Solenoid............... 8W-30-20
Fuel Pump Module................ 8W-30-4, 19
Fuel Pump Relay.................... 8W-30-4
Fuse 14........................... 8W-30-17
Fuse 15........................ 8W-30-22, 29
Fuse 16 . . 8W-30-2, 5, 7, 8, 12, 13, 18, 20, 24, 26, 28
Fuse 17.................... 8W-30-2, 4, 19, 29Component Page
Fuse 18........................ 8W-30-18, 17
Fuse 26........................... 8W-30-31
Fuselink.......................... 8W-30-26
G100.............................. 8W-30-2
G101........................... 8W-30-2, 18
G103................... 8W-30-5, 6, 18, 19, 22
G300..................... 8W-30-6, 17, 21, 30
G302........................ 8W-30-4, 19, 29
Generator....................... 8W-30-2, 19
Glow Plug No. 1.................... 8W-30-26
Glow Plug No. 2.................... 8W-30-26
Glow Plug No. 3.................... 8W-30-26
Glow Plug No. 4.................... 8W-30-26
Glow Plug Relay.................... 8W-30-26
Idle Air Control Motor............. 8W-30-11, 14
Ignition Coil..................... 8W-30-7, 13
Ignition Switch..................... 8W-30-16
Inlet Air Temperature Sensor....... 8W-30-10, 14
Integrated Power
Module.......... 8W-30-2, 3, 4, 5, 7, 8, 12, 13,
18, 19, 20, 22, 24, 26, 28, 29, 30, 31
Knock Sensor.................... 8W-30-9, 15
Leak Detection Pump................ 8W-30-16
Left Speed Control Switch........... 8W-30-3, 23
Lift Pump Motor.................... 8W-30-29
Lift Pump Relay.................... 8W-30-29
Manifold Absolute Pressure Sensor.... 8W-30-9, 15
Mass Air Flow Sensor................ 8W-30-20
Oxygen Sensor 1/1 Upstream........... 8W-30-5
Oxygen Sensor 1/2 Downstream......... 8W-30-5
Park/Neutral Position Switch.......... 8W-30-11
Power Mirror Switch................. 8W-30-17
Powertrain Control Module . 8W-30-2, 3, 4, 5, 6, 10,
11, 7, 8, 9, 12, 13, 14, 15, 16
Radiator Fan Relay................... 8W-30-3
Radiator Fan Relay No. 1............. 8W-30-31
Radiator Fan Relay No. 2............. 8W-30-31
Radiator Fan Relay No. 3............. 8W-30-31
Right Speed Control Switch......... 8W-30-3, 23
Speed Control Servo.................. 8W-30-6
Starter Motor Relay............... 8W-30-4, 19
Throttle Position Sensor........... 8W-30-10, 14
Torque Converter Clutch Solenoid....... 8W-30-16
Transmission Control Module . . 8W-30-7, 10, 11, 14
Transmission Range Sensor......... 8W-30-11, 14
Vehicle Speed Sensor............ 8W-30-7, 11, 28
Water In Fuel Sensor................ 8W-30-30
RS8W-30 FUEL/IGNITION SYSTEM8W-30-1
ProCarManuals.com

enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair theleak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
23 - 2 BODYRS
BODY (Continued)
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