Rear control CHRYSLER VOYAGER 2005 Service Manual

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Passenger Door Courtesy Lamp GY At Lamp 44
Passenger Door Lock Switch BK At Switch 44
Passenger Folding Mirror Relay
(Export)BL Left Kick Panel 7
Passenger Heated Seat Back GN At Seat N/S
Passenger Heated Seat Cushion BK At Seat N/S
Passenger Heated Seat Module GY At Heated Seat N/S
Passenger Power Seat Front
Riser MotorRD Under Seat N/S
Passenger Power Seat Horizontal
MotorBK Under Seat N/S
Passenger Power Seat Rear
Riser MotorRD Under Seat N/S
Passenger Power Seat Recliner
MotorGN Under Seat N/S
Passenger Power Seat Switch GN At Switch N/S
Passenger Power Window Motor RD At Motor 44
Passenger Power Window Switch BK At Switch 44
Passenger Seat Belt Switch
(Occupant Sensing)YL On Seat Harness N/S
Passenger Seat Belt Tensioner On Seat Harness N/S
Passenger Seat Weight Sensor BK Passenger Seat N/S
Power Folding Mirror Switch
(Export)BK Near Steering Column 31
Power Liftgate Module C1 BK Left Quarter 46, 47
Power Liftgate Module C2 Left Quarter 46, 47
Power Liftgate Motor BK Left Quarter 47
Power Mirror Switch BK Rear of Switch 30
Power Outlet (Except Lowline) BK Instrument Panel 20, 23, 25
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 BK Left Front Engine Compartment 11
Powertrain Control Module C2 OR Left Front Engine Compartment 11
Powertrain Control Module C3 NAT Left Front Engine Compartment 11
Powertrain Control Module C4 GN Left Front Engine Compartment 11
Power Window Circuit Breaker GY Left Side Kick Panel 41 42
Radiator Fan No.1 (Gas) BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 1
Radiator Fan No.2 (Gas) BK Right Side At Motor 1, 2
Radiator Fan No.2 (Diesel) GY Right Side At Motor 1, 2
Radiator Fan Relay (Gas) Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1
(Diesel)BL Left Front Engine Compartment 2
Radiator Fan Relay No. 2
(Diesel)BL Left Front Engine Compartment 2
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Radiator Fan Relay No. 3
(Diesel)BL Left Front Engine Compartment 2
Radio C1 Rear of Radio 20
Radio C2 (CD Changer) Rear of Radio 20
Radio C2 (DVD/CD Changer) Rear of Radio 20
Radio C2 (Hands Free) Rear of Radio 20
Rear A/C-Heater Unit (3 Zone
MTC)LTGN Right Quarter Panel NS
Rear Auto Temp Control Switch
(3 Zone ATC)BK Rear of Switch 50
Rear Blower Front Control Switch
(3 Zone MTC)BK Rear of Switch N/S
Rear Blower Motor Power Module
C1 (3 Zone ATC)RD/BK Right Quarter N/S
Rear Blower Motor Power Module
C2 (3 Zone ATC)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 Park Assist Display Module Overhead Console N/S
Rear Park Assist Module Left Quarter Panel 47
Rear Power Outlet GY Left Quarter Panel 47
Rear Temperature Motor (3 Zone
ATC)GY Right Quarter N/S
Rear View Mirror C1 BK At Mirror NS
Rear View Mirror C2 At Mirror N/S
Rear Window Defogger C1 Right Side of Liftgate 49
Rear Window Defogger C2 Left Side of Liftgate 49
Rear Wiper Motor At Motor 49
Recirculation Door Actuator GY Right Side of HVAC N/S
Right B-Pillar Switch (Power
Sliding Door)GY Right B Pillar 39
Right Cinch/Release Motor
(Power Sliding Door)GY Right Sliding Door 45
Right Curtain Airbag Squib Rear of Right Roof Rail 48
Right Cylinder Lock Switch
(Export)BK Right Front Door 44
Right Door Speaker At Speaker N/S
Right Fog Lamp WT At Lamp 3
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
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 BK Near T/O for C303 N/S
Right Front Park/Turn Signal
Lamp (Except Export)BK At Lamp 1, 3
Right Front Wheel Speed Sensor GY Right Fender Side Shield 3,10, 16, 17
Right Full Open Switch (Power
Sliding Door)BK Right Sliding Door 45
Right Headlamp (Caravan/
Voyager Except Export)BK At Lamp 1, 3
Right Headlamp Leveling Motor
(Export)WT At Right Headlamp N/S
Right High Beam Lamp (Export) BK At Right Headlamp N/S
Right Instrument Panel Speaker WT At Speaker 20, 23, 24
Right Liftgate Flood Lamp (Power
Liftgate)GY At Lamp 49
Right Low Beam Lamp (Export) BK At Right Headlamp N/S
Right Mid Reading Lamp
(Premium/ Luxury)GY At Lamp N/S
Right Park Lamp (Export) BK AT Lamp N/S
Right Power Mirror BK At Mirror 20, 24, 28
Right Rear Lamp Assembly BK At Lamp 48
Right Rear Pillar Speaker
(Highline Audio)BK At Speaker 48
Right Rear Reading Lamp
(Luxury)GY At Lamp N/S
Right Rear Speaker) At Speaker 48
Right Rear Vent Motor NAT At Motor 48
Right Rear Wheel Speed Sensor BK Right Rear of Floor Pan 48
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater Lamp (Export) GY Right Front Fender 39
Right Side Impact Sensor 1 Right B Pillar 39
Right Side Impact Sensor 2 Right Sliding Door 32
Right Side Impact Sensor 3 BK Right Quarter Panel 48
Right Sliding Door Control
Module C1BK Right Sliding Door 45, 46
Right Sliding Door Control
Module C2Right Sliding Door 45, 46
Right Sliding Door Latch Sensing
SwitchBK Right Sliding Door 45
Right Sliding Door Lock Motor BK Right Sliding Door 45
Right Sliding Door Lock
Motor/Ajar Switch (Manual Sliding
Door)BK Right Sliding Door N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Sliding Door Motor BK At Sliding Door 45
Right Speed Control Switch WT At Steering Wheel N/S
Right Turn Signal Lamp (Export) OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
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 (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)Left Quarter Panel N/S
Transmission Control Relay
(Diesel)Near Transmission 16
Transmission Range Sensor DKGY Top of Transmission 14, 19
Transmission Solenoid/Pressure
Switch AssemblyBK Side of Transmission 14, 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, 15, 18
G102 Left Headlamp Area 1
G103 Above Starter 15
G200 Left Side of Instrument Panel 20, 21 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)

SPLICE NUMBER LOCATION FIG.
S139 (Diesel) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C115, 16
S141 (2.4L) Near T/O for Controller Anti-Lock Brake 11
S141 (3.3L/3.8L ABS Except
Export)Near T/O for G100 N/S
S141 (Diesel) Near T/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 18
S144 (Diesel) Between T/O for Battery Temperature Sensor and T/O
for C103N/S
S148 (Diesel) Near T/O for Engine Starter Motor 5
S150 (Diesel) Near T/O for Controller Anti-Lock Brake N/S
S151 (Diesel) Near T/O for Radiator Fan Relays 2
S152 (Diesel) Near T/O for Radiator Fan No.1 N/S
S157 (Diesel) Near T/O for Glow Plug No.4 15
S177 In Right Headlamp Wiring Assembly N/S
S179 In Left Headlamp Wiring Assembly N/S
S187 (Diesel) In T/O for Engine Control Module C1 15
S188 (Diesel) Near T/O for Radiator Fan Relays 2
S189 (Diesel EATX) Near T/O for Battery (+) N/S
S190 (Diesel EATX) Near T/O for Transmission Control Module N/S
S191 (Diesel EATX) Near T/O for Transmission Control Module N/S
S192 (Diesel EATX) In T/O for Transmission Control Module N/S
S193 (Diesel EATX) In T/O for Transmission Control Module N/S
S201 In T/O to Instrument Panel Speaker 20, 26
S202 Near T/O for Instrument Panel Switch Bank 20, 26
S203 Near T/O for Instrument Panel Switch Bank 20, 26
S204 Near T/O to Instrument Panel Speaker 20, 26
S205 Near T/O for C201 N/S
S206 Near T/O for Instrument Cluster 20
S207 Near T/O for A/C Heater Control 20, 26
S208 (RHD) Between T/O for Antenna Connector and T/O for Front
Cigar Lighter26
S209 Near T/O for Evaporator Temperature Sensor N/S
S210 (RHD) Near T/O for C203 26
S211 In Steering Column Wiring Assembly N/S
S212 In Steering Column Wiring Assembly N/S
S222 Near T/O for C204 N/S
S223 Near T/O for Multi-Function Switch 20
S224 Near T/O for Siren N/S
S225 (Hands Free) Near T/O for Rear View Mirror N/S
S226 (Hands Free) In T/O for C207 N/S
S302 In Floor Pan Track Wiring 37
8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE NUMBER LOCATION FIG.
S303 In T/O to Data Link Connector 37, 41, 42
S304 (Export) In Floor Pan Track Wiring 38
S305 Near T/O for Memory Seat/Mirror Module - C2 N/S
S306 In Floor Pan Track Wiring 38
S307 Near T/O for Memory Power Seat Switch N/S
S309 In Floor Pan Track Wiring N/S
S310 Near T/O for C301 35, 36, 37
S311 In Floor Pan Track Wiring N/S
S312 Near T/O for C320 N/S
S313 Near T/O for Power Liftgate Module 47
S316 In Floor Pan Track Wiring 34
S317 Near T/O for Body Control Module 42
S318 Near T/O for Power Seat Circuit Breaker 34
S319 (Export) In Floor Pan Track Wiring 38
S321 Ner T/O for C301 35, 36, 37
S322 Near T/O for C301 37
S323 In Floor Pan Track Wiring 34
S324 In Floor Pan Track Wiring 34
S325 (Export) In Floor Pan Track Wiring 34
S326 Near T/O for C101 35, 36
S330 Near T/O for Power Liftgate Module 47
S331 Near T/O for Power Liftgate Motor 47
S332 In Floor Pan Track Wiring N/S
S333 (3 Zone MTC) In Floor Pan Track Wiring 37
S334 Near T/O to G301 34
S335 Near T/O for Left Rear Reading Lamp N/S
S336 Near T/O for Left Rear Reading Lamp N/S
S337 Near T/O for Right Mid Reading Lamp N/S
S338 Near T/O for Right Visor/Vanity Lamp N/S
S339 Near T/O for C312 N/S
S342 (LHD) Near T/O for Passenger Power Window Motor 44
S343 (LHD) Near T/O for Driver Power Window Motor 43
S344 In T/O to Right Sliding Door Control Module C2 45, 46
S345 Near T/O for Right Sliding Door Motor 45, 46
S346 Near T/O for Driver Power Window Switch 43
S347 Near T/O for Right Sliding Door Lock Motor 45, 46
S348 Near T/O for Left Sliding Door Lock Motor 46
S349 In T/O to Left Sliding Door Control Module - C2 46
S350 Near T/O for Left Sliding Door Motor 46
S352 Near T/O for Liftgate Cinch/Release Motor 49
S354 (Export) Near T/O for C301 36, 37
S354 (Except Export) Near T/O for C101 37
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-15
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE NUMBER LOCATION FIG.
S355 In T/O for C307 N/S
S356 (Export) In Floor Pan Track Wiring 37
S356 (Except Export) Near T/O for Passenger Heated Seat Back N/S
S359 Left Quarter Panel 47
S361 Near T/O for C304 N/S
S362 Near T/O for C304 N/S
S363 Near T/O for C331 N/S
S364 (RHD) Near T/O for Passenger Power Window Window 44
S365 (LHD) Near T/O for Driver Power Window Window N/S
S366 In Passenger Power Heated Seat Wiring Assembly N/S
S367 Near T/O for C301 37
S368 (Diesel) Near T/O for C101 35, 36
S370 (Except Export) In T/O for Integrated Power Module C6 7
S371 In T/O to Power Window Switch N/S
S372 Near T/O for Data Link Connector 41
S373 (Except Export In Floor Pan Track Wiring 37
S374 Near T/O for Body Control Module N/S
S376 (Highline Audio) In Floor Pan Track Wiring 34
S378 Near T/O for C301 35, 36, 37
S380 (Highline Audio) Right Quarter Panel 48
S381 (Highline Audio) Right Quarter Panel 48
S382 (Passenger Heated
Seat)Near T/O for Passenger Seat Weight Sensor N/S
S383 (Parktronics) Rear Fascia N/S
S384 (Parktronics) Rear Fascia N/S
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
OIL CONSUMPTION OR SPARK
PLUGS FOULED1. PCV system malfunction. 1. Check system and repair as
necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or
damaged.6. Replace seal(s).
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the outlet on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve outlet on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.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.
9 - 8 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
22).
(3) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(4) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.) (Fig. 20).
(5) Install timing belt and front covers (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT ANDSPROCKETS - INSTALLATION) (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
CAMSHAFT(S)
DESCRIPTION
Both camshafts have six bearing journal surfaces
and two cam lobes per cylinder (Fig. 23). Flanges at
the rear journals control camshaft end play. Provision
for a cam position sensor is located on the intake
camshaft on the rear of the cylinder head. A hydro-
dynamic oil seal is used for oil control at the front of
the camshaft.
OPERATION
The camshaft is driven by the crankshaft via drive
sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
duration.
STANDARD PROCEDURE - MEASURING
CAMSHAFT END PLAY
(1) Oil camshaft journals and install camshaft
WITHOUTrocker arms. Install rear cam caps and
tighten screws to specified torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
Fig. 21 Camshaft Oil Seal - Removal With C-4679A
1 - SPECIAL TOOL C-4679
Fig. 22 Camshaft Seal - Installation
1 - SPECIAL TOOL MD-998306
Fig. 23 Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-29
CAMSHAFT OIL SEAL(S) (Continued)

(3) Zero dial indicator (Fig. 24).
(4) Move camshaft as far forward as it will go.
(5) Record reading on dial indicator. For end play
specification, (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
(6) If end play is excessive, check cylinder head
and camshaft for wear; replace as necessary.
REMOVAL
(1) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER - REMOVAL).
(2) Remove camshaft position sensor and camshaft
target magnet (Refer to 8 - ELECTRICAL/IGNITION
CONTROL/CAMSHAFT POSITION SENSOR -
REMOVAL).
(3) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(4) Remove camshaft sprockets and timing belt
rear cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).
(5) Bearing caps are identified for location.
Remove the outside bearing caps first (Fig. 25).
(6) Loosen the camshaft bearing cap attaching
fasteners in sequence shown (Fig. 26) one camshaft
at a time.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
(7) Identify the camshafts before removing from
the head. The camshafts are not interchangeable.
(8) Remove camshafts from cylinder head.
NOTE: If removing rocker arms, identify for reinstal-
lation in the original position.
CLEANING
Clean camshaft with a suitable solvent.
INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 27). If journals are binding, check
the cylinder head for damage. Also check cylinder
head oil holes for clogging.
(2) Check the cam lobe and bearing surfaces for
abnormal wear and damage. Replace camshaft if
defective.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the rocker arms.
(3) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 27) and replace cam-
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wearlimitis 0.254 mm (0.010 in.).
Fig. 24 Camshaft End Play - Typical
Fig. 25 Camshaft Bearing Cap Identification
Fig. 26 Camshaft Bearing Cap - Removal
1 - REMOVE OUTSIDE BEARING CAPS FIRST
9 - 30 ENGINE 2.4LRS
CAMSHAFT(S) (Continued)