key CHRYSLER VOYAGER 2004 Manual PDF

Component Page
Right Front Door Lock Motor/Ajar Switch (Except
Base).......................... 8W-80-122
Right Front Impact Sensor (Except
Export)........................ 8W-80-122
Right Front Park/Turn Signal Lamp (Except
Export)........................ 8W-80-123
Right Front Wheel Speed Sensor...... 8W-80-123
Right Full Open Switch (Power Sliding
Door).......................... 8W-80-123
Right Headlamp (Except Export)...... 8W-80-123
Right Headlamp Leveling Motor
(Export)....................... 8W-80-124
Right High Beam Lamp (Export)...... 8W-80-124
Right Instrument Panel Speaker...... 8W-80-124
Right Liftgate Flood Lamp........... 8W-80-124
Right Low Beam Lamp (Export)....... 8W-80-125
Right Mid Reading Lamp (Premium/
Luxury)........................ 8W-80-125
Right Park Lamp (Export)........... 8W-80-125
Right Power Mirror................ 8W-80-125
Right Rear Lamp Assembly.......... 8W-80-126
Right Rear Pillar Speaker........... 8W-80-126
Right Rear Reading Lamp (Luxury).... 8W-80-126
Right Rear Speaker (Lowline)......... 8W-80-126
Right Rear Speaker (Highline)........ 8W-80-127
Right Rear Vent Motor.............. 8W-80-127
Right Rear Wheel Speed Sensor....... 8W-80-127
Right Remote Radio Switch.......... 8W-80-127
Right Repeater Lamp (Export)........ 8W-80-128
Right Seat Airbag.................. 8W-80-128
Right Side Impact Sensor 1 (Premium
ORC).......................... 8W-80-128
Right Sliding Door Control Module C1 (Power
Sliding Door)................... 8W-80-128Component Page
Right Sliding Door Control Module C2 (Power
Sliding Door)................... 8W-80-129
Right Sliding Door Latch Sensing Switch (Power
Sliding Door)................... 8W-80-129
Right Sliding Door Lock Motor (Power Sliding
Door).......................... 8W-80-129
Right Sliding Door Lock Motor/Ajar Switch (Manual
Sliding Door)................... 8W-80-130
Right Sliding Door Motor (Power Sliding
Door).......................... 8W-80-130
Right Speed Control Switch.......... 8W-80-130
Right Turn Signal Lamp (Export)...... 8W-80-130
Right Visor/Vanity Lamp (Premium/Luxury Except
Export)........................ 8W-80-131
Sentry Key Remote Entry Module
(SKREEM)..................... 8W-80-131
Siren (United Kingdom)............. 8W-80-131
Speed Control Servo (Gas)........... 8W-80-131
Sunroof Module (Except Export)....... 8W-80-132
Sunroof Switch (Except Export)....... 8W-80-132
Thatcham Alarm Module (United
Kingdom)...................... 8W-80-132
Throttle Position Sensor (Gas)........ 8W-80-133
Traction Control Switch............. 8W-80-133
Trailer Tow Connector (Except Export) . . 8W-80-133
Transmission Range Sensor.......... 8W-80-133
Transmission Solenoid/Pressure Switch
Assembly...................... 8W-80-134
Vehicle Speed Sensor (MTX).......... 8W-80-134
Washer Fluid Level Switch........... 8W-80-134
Washer Pump Motor................ 8W-80-134
Water In Fuel Sensor (Diesel)......... 8W-80-135
Wiper Module..................... 8W-80-135
RS8W-80 CONNECTOR PIN-OUTS8W-80-5

REAR TEMPERATURE MOTOR (3 ZONE ATC) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 C54 18LB/YL REAR BLEND DOOR DRIVER (A)
2 C169 18LB/TN REAR BLEND DOOR DRIVER (B)
REAR WIPER MOTOR - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z213 18BK/LG GROUND
2 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
3 W13 18BR/LG REAR WIPER MOTOR CONTROL
RECIRCULATION DOOR ACTUATOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 C132 20DB/YL (ATC) RECIRCULATION DOOR DRIVER (B)
1 C34 20DB/LB (LHD) COMMON DOOR DRIVER (B)
1 C32 20DB/TN (RHD) RECIRCULATION DOOR DRIVER (A)
2 C32 20DB/TN (ATC) RECIRCULATION DOOR DRIVER (A)
2 C32 20DB/TN (LHD) RECIRCULATION DOOR DRIVER (A)
2 C34 20DB/LB (RHD) COMMON DOOR DRIVER (B)
REMOTE KEYLESS ENTRY ANTENNA (JAPAN) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 D10 18WT REMOTE KEYLESS ENTRY ANTENNA (+)
2 D10 18WT/LB REMOTE KEYLESS ENTRY ANTENNA (-)
RIGHT B-PILLAR SWITCH (POWER SLIDING DOOR) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z62 22BK/YL GROUND
2- -
3 G42 22VT/YL RIGHT SLIDING DOOR PILLAR SWITCH MUX
8W - 80 - 120 8W-80 CONNECTOR PIN-OUTSRS

RIGHT VISOR/VANITY LAMP (PREMIUM/LUXURY EXCEPT EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A Z327 20BK/OR GROUND
B M27 20YL/LB READING LAMPS DRIVER
SENTRY KEY REMOTE ENTRY MODULE (SKREEM) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 D10 18WT (RHD) REMOTE KEYLESS ENTRY ANTENNA (+)
2 D25 20WT/VT PCI BUS
3 D10 18WT/LB (RHD) REMOTE KEYLESS ENTRY ANTENNA (-)
4 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 Z120 22BK/WT GROUND
6 A114 20GY/RD FUSED B(+) (I.O.D.)
SIREN (UNITED KINGDOM) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1- -
2 D96 18WT/LB SIREN SIGNAL CONTROL
3 A114 18GY/RD FUSED B(+) (I.O.D.)
4 Z109 18BK/GY GROUND
SPEED CONTROL SERVO (GAS) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 18VT/YL S/C VACUUM CONTROL
2 V35 18VT/OR S/C VENT CONTROL
3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT
4 Z155 18BK/LG GROUND
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 131

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Radio C2 (CD Changer) Rear of Radio 20
Radio C2 (DVD/CD Changer) At Radio N/S
Rear A/C-Heater Unit (3 Zone
MTC)LTGN Right Quarter Panel 48
Rear Auto Temp Control Switch
(ATC)BK Rear of Switch 40
Rear Blower Front Control Switch
(3 Zone MTC)BK Rear of Switch N/S
Rear Blower Motor Power Module
C1 (3 Zone MTC)RD/BK Right Quarter N/S
Rear Blower Motor Power Module
C2 (3 Zone MTC)BK Right Quarter N/S
Rear Blower Rear Control Switch
C1 (3 Zone MTC)BK Overhead 50
Rear Blower Rear Control Switch
C2 (3 Zone MTC)BK Overhead 50
Rear Dome Lamp (Except
Luxury)GY At Lamp N/S
Rear Intrusion Sensor (United
Kingdom)At Sensor N/S
Rear Mode Motor (3 Zone ATC) GY At Motor N/S
Rear Power Outlet GY Left Quarter Panel 47
Rear Temperature Motor (3 Zone
ATC)GY Right Quarter N/S
Rear Washer Pump Motor BK Right Fender Well 3
Rear Wiper Motor GY At Motor 49
Recirculation Door Actuator GY Right Side of HVAC N/S
Remote Keyless Entry Antenna
(JAPAN)BK Right Upper Instrument Panel 28
Right B-Pillar Switch (Power
Sliding Door)GY Right B Pillar 39
Right Cinch/Release Motor
(Power Sliding Door)GY Rear of Sliding Door 45
Right Cylinder Lock Switch
(Export)BK Right Front Door 44
Right Door Speaker (Highline) BK/RD At Speaker N/S
Right Door Speaker (Lowline) In Door N/S
Right Fog Lamp (Export) WT At Lamp 3
Right Fog Lamp (Except Export) BK At Lamp N/S
Right Front Door Ajar Switch
(Base)BK At B Pillar N/S
Right Front Door Lock Motor/Ajar
Switch (Except Base)BK Right Front Door 44
Right Front Impact Sensor
(Except Export)BK Near T/O for C303 N/S
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Sentry Key Remote Entry Module
(Skreem)BK At Steering Column 20, 21, 22, 23, 31
Siren (United Kingdom) BK Left Front Body N/S
Speed Control Servo (Gas) BK Near Controller Antilock Brake 11, 17, 18
Sunroof Module (Except Export) BK At Sunroof N/S
Sunroof Switch (Except Export) Nat Near Overhead Console N/S
Thatcham Alarm Module C1
(United Kingdom)BK Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor (Gas) GY On Throttle Body 10, 11, 17
Traction Control Switch BK Rear of Swtich 21, 22, 31
Trailer Tow Connector (Except
Export)BK Left Quarter Panel N/S
Transmission Range Sensor DKGY Top of Transmission 14, 19
Transmission Solenoid/Pressure
Switch AssemblyBK Side of Transmission 14, 18 19
Vehicle Speed Sensor (MTX) BK Rear of Transmission 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Washer Pump Motor BK Right Fender Well 3
Water in Fuel Sensor (Diesel) BK Left Rear Engine Compartment N/S
Wiper Module DKGY Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 13, 18
G102 Left Headlamp Area 1
G103 Above Starter 15
G200 Right Side of Instrument Panel 20, 24, 29
G201 Right Side of Instrument Panel 20, 24, 29
G202 Near Radio N/S
G300 Left B Pillar 32
G301 Right B Pillar 33, 39
G302 Left Rear Quarter 47
G303 Liftgate Ground 49
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Check the fused B(+) fuse in the Integrated
Power Module (IPM). If OK, go to Step 2. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3) Open the power outlet door. Check for continu-
ity between the inside circumference of the power
outlet receptacle and a good ground. There should be
continuity. If OK, go to Step 4. If not OK, go to Step
5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector and a good ground.
There should be continuity. If OK, go to Step 6. If not
OK, repair the open ground circuit to ground as
required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEMRS

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Look inside and note position of the retaining
bosses (Fig. 4).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 5).(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the
9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3) Push the base into the bezel until it locks in
place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 4 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 5 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
POWER OUTLET (Continued)

OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove crankshaft sprocket using Special
Tools 6793 and C-4685-C2 (Fig. 90).
(6) Remove crankshaft key (Fig. 91).
(7) Remove oil pick-up tube.(8) Remove oil pump (Fig. 92) and front crankshaft
seal.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 93) .
(b) Remove spring and relief valve (Fig. 93) .
Fig. 90 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 91 Crankshaft Key
1 - CRANKSHAFT KEY
Fig. 92 Oil Pump
1 - BOLTS
2 - BOLTS
3 - OIL PUMP
Fig. 93 Oil Pressure Relief Valve
1 - PLUG
2 - OIL PUMP BODY
3 - RELIEF VALVE
4 - SPRING
5 - SEAL
RSENGINE 2.4L9-55

CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 93) or serious engine
damage may occur.
(4) Install relief valve, spring, gasket and cap as
shown in (Fig. 93). Tighten cap to 41 N´m (30 ft.
lbs.).
INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 98). Install O-ring into oil pump body
discharge passage.
(3) Prime oil pump with engine oil before installa-
tion.
(4) Align oil pump rotor flats with flats on crank-
shaft. Install the oil pump to the block (Fig. 92).
CAUTION: To align, the front crankshaft seal MUST
be out of pump, or damage may result.
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 99).
(6) Install crankshaft key (Fig. 91).
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(7) Install crankshaft sprocket using Special Tool
6792 (Fig. 100).
(8) Install oil pump pick-up tube.
(9) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).(10) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(11) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
Fig. 98 Oil Pump Sealing
1 - O-RING
2 - SEALER LOCATION
Fig. 99 Front Crankshaft Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 100 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-57
OIL PUMP (Continued)

INSTALLATION
BALANCE SHAFT INSTALLATION/TIMING
Balance shaft and carrier assembly installation is
the reverse of the removal procedure.During instal-
lation crankshaft-to-balance shaft timing must
be established. Refer to Timing procedure in
this section.
(1) With balance shafts installed in carrier (Fig.
130) position carrier on crankcase and install four
attaching bolts and tighten to 54 N´m (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways
are up, parallel to vertical centerline of engine.
Install short hub drive gear on sprocket driven shaft
and long hub gear on gear driven shaft. After instal-
lation gear and balance shaft keyways must be up
with gear timing marks meshed as shown in (Fig.
135).
(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
(4) Align flat on balance shaft drive sprocket to the
flat on crankshaft (Fig. 136).
(5) Install balance shaft drive sprocket on crank-
shaft using Special Tool 6052 (Fig. 137).
(6) Turn crankshaft until number 1 cylinder is at
top dead center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(Fig. 138).
(7) Place chain over crankshaft sprocket so that
the plated link of the chain is over the number 1 cyl-
inder timing mark on the balance shaft crankshaft
sprocket (Fig. 138).
(8) Place balance shaft sprocket into the timing
chain (Fig. 138) and align the timing mark on the
sprocket (dot) with the (lower) plated link on the
chain.NOTE: The lower plated link is 8 links from the
upper link.
Fig. 135 Gear Timing
1 - KEY WAYS UP
2 - GEAR ALIGNMENT DOTS
Fig. 136 Balance Shaft Sprocket Alignment to
Crankshaft
1 - ALIGN FLATS
Fig. 137 Balance Shaft Drive
1 - SPROCKET
2 - SPECIAL TOOL 6052
9 - 72 ENGINE 2.4LRS
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)