battery CHRYSLER VOYAGER 2003 Service Manual

REMOVAL - 2.5L TD
(1) Raise hood.
(2) Disconnect both battery cables.
(3) Remove battery thermal shield (Fig. 15).
(4) Remove battery hold down bolt, clamp, and
battery (Fig. 16).(5) Remove battery tray (Fig. 17). Disconnect bat-
tery temperature sensor.
(6) Remove coolant recovery bottle from bracket.
(7) Remove coolant recovery bottle mounting
bracket (Fig. 18).
(8) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 19).
(9) Remove gearshift cable retaining clips from
mounting bracket (Fig. 19). Remove cables and
secure out of way.
Fig. 15 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 16 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 17 Battery Tray
1 - BATTERY TRAY
Fig. 18 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
RST850 MANUAL TRANSAXLE21-33
T850 MANUAL TRANSAXLE (Continued)
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(13) Install right mount bracket to transaxle (Fig.
80).
(14) Connect gearshift cables to shift levers/cover
assembly (Fig. 81). Install cables into position at
mount bracket and secure with retaining clips.
(15) Connect battery cables.
(16) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
INSTALLATION - 2.5L TD
(1) Assemble transaxle to engine, while aligning
transaxle input shaft to clutch disc splines.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.) (Fig. 82).
(3) Install transaxle upper mount (Fig. 83). Install
and torque four (4) mount-to-transaxle bolts to 54
N´m (40 ft. lbs.).
(4) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(5) Remove screw jack.
(6) Connect back-up lamp switch connector.
(7) Install starter motor into position (Fig. 84).
Install and torque bolts to 54 N´m (40 ft. lbs.).
Fig. 80 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 81 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
21 - 52 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(15) Install coolant recovery bottle bracket (Fig.
88).
(16) Install coolant recovery bottle to bracket.
(17) Connect battery temperature sensor and
install battery tray (Fig. 89).(18) Install battery, hold-down clamp and nut (Fig.
90).
(19) Install battery thermal shield and clutch cable
eyelet (Fig. 91).
(20) Connect battery cables.
(21) Check transaxle fluid and engine coolant lev-
els. Adjust if necessary. (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/MANUAL/FLUID - STANDARD
PROCEDURE)
Fig. 88 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
Fig. 89 Battery Tray
1 - BATTERY TRAY
Fig. 90 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 91 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
RST850 MANUAL TRANSAXLE21-55
T850 MANUAL TRANSAXLE (Continued)
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INSTALLATION
(1) Install gearshift boot to console and secure
with three (3) retaining clips (Fig. 130).
(2) Install gearshift knob (Fig. 129). Orient shift
pattern
1¤4-turn clockwise, press down, and rotate1¤4-
turn counter-clockwise.
(3) Secure gearshift boot to base of knob.
GEARSHIFT CABLE -
CROSSOVER
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 131).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 132).
(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
133).
Fig. 131 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 132 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 133 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
RST850 MANUAL TRANSAXLE21-73
GEARSHIFT BOOT (Continued)
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(10)2.4L Gas equipped models goto Step 15.
2.5L TD models:Remove battery thermal shield
(Fig. 138).
(11) Remove battery hold down nut, clamp, and
battery (Fig. 139).(12) Remove battery tray (Fig. 140). Disconnect
battery temperature sensor.
(13) Remove coolant recovery bottle from bracket.
(14) Remove coolant recovery bottle mounting
bracket (Fig. 141).
Fig. 138 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 139 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 140 Battery Tray
1 - BATTERY TRAY
Fig. 141 Coolant Recovery Bottle Bracket
1 - COOLANT RECOVERY BOTTLE BRACKET
2 - NUT
3 - MOUNT BRACKET
RST850 MANUAL TRANSAXLE21-75
GEARSHIFT CABLE - CROSSOVER (Continued)
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(6) Install coolant recovery bottle to bracket.
(7) Connect battery temperature sensor to battery
tray. Install battery tray into position (Fig. 145).
(8) Install battery, hold-down clamp, and nut (Fig.
146).(9) Install battery thermal shield (Fig. 147).
(10) Install crossover cable to gearshift mechanism
(Fig. 148). Install retainer clip (Fig. 149).
Fig. 145 Battery Tray
1 - BATTERY TRAY
Fig. 146 Battery and Hold-Down Clamp
1 - BATTERY
2 - HOLD-DOWN CLAMP
Fig. 147 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
Fig. 148 Crossover Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - CROSSOVER CABLE
RST850 MANUAL TRANSAXLE21-77
GEARSHIFT CABLE - CROSSOVER (Continued)
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(15) Install gearshift boot to console (Fig. 153).
Secure with three (3) retainer clips.
(16) Install gearshift knob to gearshift lever (Fig.
154). Orient shift pattern
1¤4-turn clockwise, push
down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(17) Connect battery negative cable.
ADJUSTMENTS
ADJUSTMENT
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 155).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 156).
Fig. 153 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 154 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 155 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 156 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
RST850 MANUAL TRANSAXLE21-79
GEARSHIFT CABLE - CROSSOVER (Continued)
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(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
157).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
158).(7) Loosen crossover cable adjustment screw (Fig.
159).
(8) Rock gearshift lever back and forth between
1±2 and 5±R planes. Release lever, allowing shifter
spring to return lever to the neutral position in the
3±4 plane. Place gearshift lever in the 3rd gear posi-
tion.
(9) Torque crossover lever adjustment screw to 8
N´m (70 in. lbs.).No load should be applied to
the shifter lever in any direction (hands off)
while tightening screw.
(10) Verify gearshift lever travel through all gear
ranges with engine off (not running).
(11) Install center console assembly (Fig. 158).
Install and torque center console-to-gearshift mecha-
nism screws to 5 N´m (45 in. lbs.).
(12) Install cupholder plugs (Fig. 157).
(13) Install gearshift boot to console (Fig. 156).
Secure boot to console with three (3) retainer clips.
(14) Install gearshift knob to gearshift lever (Fig.
155). Orient shift pattern on knob
1¤4-turn clockwise,
push down and rotate1¤4-turn counter-clockwise and
release. Secure boot to knob.
(15) Connect battery negative cable.
Fig. 157 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 158 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
Fig. 159 Crossover Cable Adjustment Screw
1 - CROSSOVER CABLE
2 - ADJUSTMENT SCREW
21 - 80 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - CROSSOVER (Continued)
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GEARSHIFT CABLE -
SELECTOR
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove gearshift knob by pushing down and
rotating
1¤4-turn clock-wise (Fig. 160).
(3) Remove gearshift boot from center console by
disengaging at three (3) retaining clips (Fig. 161).(4) Apply park brake to allow park brake handle to
clear center console upon removal.
(5) Remove two (2) cupholder bottom plugs (Fig.
162).
(6) Remove four (4) center console-to-gearshift
mechanism screws. Remove console assembly (Fig.
163).
Fig. 160 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
2 - GEARSHIFT LEVER
Fig. 161 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
2 - CENTER CONSOLE
Fig. 162 Cup Holder Plugs
1 - CUPHOLDER PLUG (2)
Fig. 163 Center Console Removal/Installation (LHD
Shown Ð RHD Typical)
1 - CENTER CONSOLE
2 - SCREW (4)
3 - GEARSHIFT MECHANISM
RST850 MANUAL TRANSAXLE21-81
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(7) Remove center console support bracket (Fig.
164).
(8) Remove selector cable retainer clip (Fig. 165).(9) Remove selector cable from gearshift mecha-
nism (Fig. 166).
(10)2.4L Gas models goto Step 15. 2.5L TD
Models:Remove battery thermal shield (Fig. 167).
Fig. 164 Center Console Support Bracket
1 - BRACKET
2 - SCREW
3 - GEARSHIFT MECHANISM
Fig. 165 Selector Cable Retainer Clip
1 - RETAINER CLIP
Fig. 166 Selector Cable at Gearshift Mechanism
1 - GEARSHIFT MECHANISM
2 - SELECTOR CABLE
Fig. 167 Battery Thermal Shield
1 - BATTERY THERMAL SHIELD
21 - 82 T850 MANUAL TRANSAXLERS
GEARSHIFT CABLE - SELECTOR (Continued)
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