ad blue CHRYSLER VOYAGER 2005 User Guide

PASSENGER DOOR COURTESY LAMP (LUXURY/EXPORT) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z322 20BK/BR (LHD) GROUND
1 Z321 20BK/BR (RHD) GROUND
2- -
3 M21 14YL/BR (EXCEPT EXPORT) COURTESY LAMPS DRIVER
3 M21 20YL/BR (EXPORT) COURTESY LAMPS DRIVER
PASSENGER DOOR LOCK SWITCH - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1- -
2 G160 20VT/LG (LHD) RIGHT DOOR LOCK SWITCH MUX
2 G161 20VT/DG (RHD) LEFT DOOR LOCK SWITCH MUX
3 Z460 20BK/LG (LHD) GROUND
3 Z461 20BK/DG (RHD) GROUND
PASSENGER FOLDING MIRROR RELAY (EXPORT) - BLUE 9 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 A108 20LG/RD FUSED B(+)
5 P164 18LG/DB PASSENGER FOLDING MIRROR RELAY INPUT
6 P162 18LG/DG PASSENGER FOLDING MIRROR RELAY CONTROL
7- -
8 P160 18TN/LG PASSENGER FOLDING MIRROR RELAY OUTPUT
9- -
PASSENGER HEATED SEAT BACK - LT. GREEN 2 WAY
CAV CIRCUIT FUNCTION
A S1 16DB (EXCEPT EXPORT) SEAT HEATER B(+) DRIVER
A S1 18WT (EXPORT) SEAT HEATER B(+) DRIVER
B Z848 16BK/OR (EXCEPT EXPORT) GROUND
B S2 18GY (EXPORT) SEAT HEATER GROUND
8W - 80 - 108 8W-80 CONNECTOR PIN-OUTSRS

RADIATOR FAN RELAY (GAS)-4WAY
CAV CIRCUIT FUNCTION
1 A112 12OR/RD FUSED B(+)
2 N23 12DB/DG RADIATOR FAN RELAY OUTPUT
3 Z723 18BK/DG GROUND
4 N173 18DB/VT RAD FAN RELAY CONTROL
RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY
CAV CIRCUIT FUNCTION
1- -
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5- -
6 N210 18DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
7- -
8 A201 12RD/LG FUSED B(+)
9- -
RADIATOR FAN RELAY NO. 2 (DIESEL) - BLUE 9 WAY
CAV CIRCUIT FUNCTION
1- -
2 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON
OUTPUT
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5- -
6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
7- -
8 A112 12OR/RD FUSED B(+)
9- -
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 121

RADIATOR FAN RELAY NO. 3 (DIESEL) - BLUE 9 WAY
CAV CIRCUIT FUNCTION
1- -
2 Z823 12BK/DG GROUND
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON
OUTPUT
6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
7- -
8 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
9- -
RADIO C1 - 22 WAY
CAV CIRCUIT FUNCTION
1 A114 16GY/RD FUSED B(+) (I.O.D.)
2 F306 18DB/PK FUSED ACCESSORY RELAY OUTPUT
3 E14 20OR/TN PANEL LAMPS DRIVER
4- -
5- -
6- -
7 X54 20GY (LOWLINE) RIGHT FRONT SPEAKER (+)
8 X56 20GY/BR (LOWLINE) RIGHT FRONT SPEAKER (-)
9 X55 20DG/BR (LOWLINE) LEFT FRONT SPEAKER (-)
10 X53 20DG (LOWLINE) LEFT FRONT SPEAKER (+)
11 Z514 16BK/LG GROUND
12 A114 16GY/RD FUSED B(+) (I.O.D.)
13 X60 20GY/YL (EXPORT) RADIO 12 VOLT OUTPUT
14 D25 20WT/VT PCI BUS
15 - -
16 - -
17 - -
18 X51 22DG/DB LEFT REAR SPEAKER (+)
19 X57 22DG/OR LEFT REAR SPEAKER (-)
20 X58 22GY/OR RIGHT REAR SPEAKER (-)
21 X52 22GY/DB RIGHT REAR SPEAKER (+)
22 Z515 16BK GROUND
8W - 80 - 122 8W-80 CONNECTOR PIN-OUTSRS

(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 the
crankshaft 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 TEST
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) Remove the Auto Shutdown (ASD) relay from
the PDC.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gauge adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer (Special Tool CH7059) with cable adap-
tors to the DRBIIIt. For Special Tool identification,
(Refer to 9 - ENGINE - SPECIAL TOOLS).
(7) Crank engine until maximum pressure is
reached on gauge. Record this pressure as #1 cylin-
der 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
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the pressure cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
RSENGINE 2.4L9-9
ENGINE 2.4L (Continued)

(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 the
crankshaft 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 TEST
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) Remove the Auto Shutdown (ASD) relay from
the PDC.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gauge adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer (Special Tool CH7059) with cable adap-
tors to the DRBIIIt. For Special Tool identification,
(Refer to 9 - ENGINE - SPECIAL TOOLS).
(7) Crank engine until maximum pressure is
reached on gauge. Record this pressure as #1 cylin-
der 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
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the pressure cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
RSENGINE 3.3/3.8L9-85
ENGINE 3.3/3.8L (Continued)

CYLINDER HEAD COVER -
LEFT
REMOVAL
(1) Disconnect spark plug wires from spark plugs.
(2) Disconnect crankcase vent hose from cylinder
head cover.
(3) Remove cylinder head cover bolts.
(4) Remove cylinder head cover and gasket.
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Assemble gasket to cylinder cover by inserting
the fasteners through each bolt hole on cover and
gasket (Fig. 25).
(3) Install the cylinder head cover and bolts (Fig.
26).
(4) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 26).
(5) Connect crankcase vent hose.
(6) Connect spark plug wires to spark plugs.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves have chrome plated valve stems with
four-bead lock grooves. The valve stem seals are
made of Viton rubber.
OPERATION
The two valves per cylinder are opened using
hydraulic lifters, push rods, and rocker arms.
STANDARD PROCEDURE - REFACING VALVES
AND VALVE SEATS
The intake and exhaust valves and seats are
machined to specific angles (Fig. 27).
VALVES
(1) Inspect the remaining margin after the valves
are refaced (Fig. 28). (Refer to 9 - ENGINE - SPEC-
IFICATIONS)
VALVE SEATS
CAUTION: Remove metal from valve seat only. Do
not remove material from cylinder head (Fig. 29).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.(2) Measure the concentricity of valve seat using
dial indicator (Fig. 30). Total runout should not
exceed 0.051 mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat using Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of valve face, lower valve seat with
a 15 degree stone. If the blue is transferred to the
bottom edge of valve face raise valve seat with a 65
degrees stone.
Fig. 27 VALVE FACE AND SEAT
1 - VALVE FACE WIDTH
2 - VALVE FACE ANGLE
3 - SEAT ANGLE
4 - SEAT CONTACT AREA
Fig. 28 Valve Margin
1 - VALVE FACE
2 - VALVE MARGIN
RSENGINE 3.3/3.8L9 - 107

of the handle bracket and then unhook swedged
cable end from the handle link.
(6) Open the side door and remove the latch
assembly. Refer to the Power Side Doors section for
the procedure.
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(7) Trace the inside handle cable along its routing
path and disconnect from its retaining clips.
(8) Disconnect the inside handle cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(9) Remove the inside handle cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Match the replacement cable up against the old
cable to verify the correct part.
(2) Position the inside handle cable on the side
door.
(3) Connect the inside handle cable on the handle
assembly. Hook the swedged cable end on the handle
link and gently push the cable sleeve retainer in the
handle bracket.
(4) Install the inside handle assembly on the side
door. (Refer to 23 - BODY/DOORS - SLIDING/IN-
SIDE LATCH HANDLE - INSTALLATION)
NOTE: The inside handle cable is marked with blue
tape and must be attached to the latch at the center
(just above the lower cable). This position is
marked with a ªBº on the latch.
(5) Connect the inside handle cable on the latch
assembly. Hook the swedged cable end on the latch
link and gently push the cable sleeve retainer in the
latch bracket.
(6) Trace the inside handle cable along its routing
path and install on its retaining clips and position
foam insulators. Use previously made schematic as a
guide or remove the opposite side door trim panel
and use that door as a guide.
CAUTION: Be certain replacement cable is routed
and retained correctly and foam insulators are
properly positioned.(7) Install the latch assembly. Refer to the Power
Side Doors section for the procedure.
(8) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(9) Install the appropriate side door trim panel on
the vehicle. (Refer to 23 - BODY/DOORS - SLIDING/
TRIM PANEL - INSTALLATION)
(10) Connect the negative battery cable.
HOLD OPEN LATCH CABLE
REMOVAL
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate side door trim panel
from the vehicle. (Refer to 23 - BODY/DOORS -
SLIDING/TRIM PANEL - REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel.
(4) Open the side door and remove the latch
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/LATCH - REMOVAL)
CAUTION: Make note of cable routing and foam
insulator placement. This will prove helpful when
reinstalling replacement cable. Be certain replace-
ment cable is routed and retained correctly.
(5) Trace the hold open latch cable along its rout-
ing path and disconnect from its retaining clips.
(6) Disconnect the hold open latch cable from the
latch assembly. Gently pry cable sleeve retainer out
of the latch mounting bracket and then unhook
swedged cable end from the latch link.
(7) Remove the hold open latch from the side door.
(Refer to 23 - BODY/DOORS - SLIDING/HOLD
OPEN LATCH - REMOVAL)
(8) Disconnect the hold open latch cable from the
hold open latch. Gently pry cable sleeve retainer out
of the handle bracket and then unhook swedged
cable end from the latch link.
(9) Remove the hold open latch cable from the side
door.
INSTALLATION
NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section.
23 - 38 DOORS - SLIDINGRS
INSIDE HANDLE CABLE (Continued)

PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - COLOR CODE CHARTS . . 100
BASE COAT/CLEARCOAT FINISH
DESCRIPTION........................101
PAINT CODE
DESCRIPTION........................101PAINTED TOUCH-UP
DESCRIPTION........................101
FINESSE SANDING/BUFFING & POLISHING
DESCRIPTION........................101
PAINT
SPECIFICATIONS - COLOR CODE CHARTS
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
COLOR CODEEXTERIOR COLOR DAIMLERCHRYSLER
COLOR CODE
BRIGHT SILVER
METALLIC CLEAR
COATWS2 LIGHT KHAKI
METALLIC CLEAR
COATAJC
BRILLIANT BLACK
CRYSTAL PEARL
COATAXR LINEN GOLD PEARL
COATCYG
BUTANE BLUE
METALLIC CLEAR
COATABE MAGNESIUM PEARL
COATBPK
DARK KHAKI
METALLIC CLEAR
COATBJT MIDNIGHT BLUE
PEARL COATBB8
DEEP BERYL GREEN
PEARL COATCGV PATRIOT BLUE
PEARL COATWB7
DEEP LAVA RED
PEARL COATZMQ SATIN JADE PEARL
COATAP4
DEEP MOLTEN RED
PEARL COATBR8 SHALE GREEN
METALLIC CLEAR
COATWS2
GRAPHITE METALLIC
CLEAR COATZDR STONE WHITE CLEAR
COATSW1
INFERNO RED TINTED
PEARL COATWEL
23 - 100 PAINTRS

MANIFOLD GAUGE SET
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
A manifold gauge set may be needed with some
recovery/recycling/charging equipment (Fig. 3). The
service hoses on the gauge set being used should
have manual (turn wheel), or automatic back-flow
valves at the service port connector ends. This will
prevent refrigerant from being released into the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
²LOW PRESSURE GAUGE HOSE- The low
pressure hose (Blue with Black stripe) attaches to
the low side service port. This service port is located
on the suction line near the A/C compressor.
²HIGH PRESSURE GAUGE HOSE- The high
pressure hose (Red with Black stripe) attaches to the
high side service port. This service port is located on
the liquid line fitting at the reciever/drier.
²RECOVERY/RECYCLING/EVACUATION/
CHARGING HOSE- The center manifold hose (Yel-
low, or White, with Black stripe) is used to recover,
evacuate, and charge the refrigerant system. When
the low or high pressure valves on the manifold
gauge set are opened, the refrigerant in the system
will escape through this hose.
REFRIGERANT SYSTEM RECOVERY
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING).
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.
REFRIGERANT SYSTEM EVACUATE
NOTE: Special effort must be used to prevent mois-
ture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a
reliability problem with the compressor.
Fig. 2 Refrigerant Recovery/Recycling Station -
Typical
1 - R-134a REFRIGERANT STATION
Fig. 3 Manifold Gauge Set - Typical
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK STRIPE)
4 - HIGH PRESSURE HOSE (RED W/BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
24 - 70 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)