2004 CHRYSLER VOYAGER Service and Repair Manual
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TABLE OF CONTENTS
1.0 INTRODUCTION .........................................................1
1.1 SYSTEM COVERAGE ...............................................1
1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1
2.0 IDENTIFICATION OF SYSTEM .............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1
3.1 ADJUSTABLE PEDALS SYSTEM ......................................2
3.2 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM AND
OCCUPANT CLASSIFICATION SYSTEM ................................2
3.2.1 DRIVER AIRBAG............................................3
3.2.2 CLOCKSPRING.............................................4
3.2.3 PASSENGER AIRBAG .......................................4
3.2.4 SEAT BELT TENSIONER (SBT) ................................6
3.2.5 SEAT BELT SWITCHES (SBS).................................6
3.2.6 DRIVER KNEE BLOCKER AIRBAG .............................6
3.2.7 FRONT AND SIDE IMPACT SENSOR ...........................6
3.2.8 OCCUPANT CLASSIFICATION SYSTEM ........................6
3.2.9 SPECIAL TOOLS............................................9
3.2.10 DIAGNOSTIC TROUBLE CODES ..............................9
3.2.10.1 ACTIVE CODES ............................................9
3.2.10.2 STORED CODES ...........................................9
3.3 AUDIO SYSTEM ...................................................10
3.3.1 NAVIGATION RADIO........................................10
3.3.2 REMOTE RADIO CONTROLS ................................10
3.3.3 CD CHANGER .............................................11
3.3.4 DVD/CD CHANGER ........................................11
3.4 BODY CONTROL MODULE ..........................................11
3.5 CHIME WARNING SYSTEM .........................................12
3.5.1 CHIME PRIORITY ..........................................12
3.5.2 CHIME ON CONDITIONS....................................12
3.5.3 WARNING LAMP ANNOUNCEMENT ..........................13
3.5.4 OTHER CHIME ON CONDITIONS.............................13
3.6 COMMUNICATION .................................................13
3.7 DOOR AJAR SYSTEM ..............................................15
3.8 EXTERIOR LIGHTING SYSTEM ......................................15
3.8.1 HEADLAMP POWER .......................................15
3.8.2 HEADLAMP SWITCH .......................................15
3.8.3 PARK LAMP RELAY ........................................15
3.8.4 FOG LAMP RELAY .........................................15
3.8.5 FOG LAMPS ..............................................15
3.8.6 EXTERIOR LIGHTING BATTERY SAVER .......................16
3.8.7 AUTO HEADLAMPS ........................................16
3.9 FRONT CONTROL MODULE .........................................16
3.9.1 CONTROLLED POWER FEEDS ..............................16
3.9.2 RELAY CONTROLS ........................................17
3.9.3 ELECTRICAL INPUTS ......................................18
3.10 HEATING & A/C SYSTEM ...........................................19
3.10.1 AUTOMATIC TEMPERATURE CONTROL (ATC) .................19
3.10.1.1 MODULE USAGE ..........................................19
3.10.1.2 SYSTEM AVAILABILITY .....................................19
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TABLE OF CONTENTS - Continued
3.10.1.3 SYSTEM CONTROLS .......................................19
3.10.1.4 SYSTEM REVISIONS .......................................20
3.10.1.5 SYSTEM DIAGNOSTICS ....................................20
3.10.2 MANUAL TEMPERATURE CONTROL (MTC) ....................21
3.10.2.1 MODULE USAGE ..........................................21
3.10.2.2 SYSTEM AVAILABILITY .....................................21
3.10.2.3 SYSTEM CONTROLS .......................................22
3.10.2.4 SYSTEM REVISIONS .......................................23
3.10.2.5 SYSTEM DIAGNOSTICS ....................................23
3.11 CABIN HEATER ...................................................24
3.11.1 GENERAL SAFETY INFORMATION ...........................24
3.11.2 COMPONENT DESCRIPTION AND OPERATION ................25
3.11.2.1 DCHA ASSEMBLY..........................................25
3.11.2.2 COMBUSTION AIR FAN .....................................25
3.11.2.3 BURNER HOUSING ........................................25
3.11.2.4 BURNER INSERT ..........................................25
3.11.2.5 CONTROL UNIT/HEAT EXCHANGER ..........................25
3.11.2.6 DOSING PUMP ............................................25
3.11.3 OPERATION ..............................................25
3.11.3.1 VENTING THE DCHA’S EXHAUST ............................25
3.11.3.2 ACTIVATION ..............................................26
3.11.3.3 HEATING .................................................27
3.11.3.4 DEACTIVATION ............................................27
3.11.3.5 SYSTEM REVISIONS .......................................27
3.11.4 DIAGNOSTICS ............................................27
3.12 INSTRUMENT CLUSTER ............................................27
3.12.1 INSTRUMENT CLUSTER SELF TEST .........................28
3.12.2 MESSAGE CENTER (EXPORT ONLY) .........................28
3.13 INTERIOR LIGHTING ...............................................28
3.13.1 COURTESY LAMP CONTROL ................................28
3.13.2 ILLUMINATED ENTRY ......................................28
3.13.3 INTERIOR LIGHTING BATTERY SAVER .......................28
3.14 MEMORY SYSTEM.................................................28
3.14.1 POWER SEAT .............................................29
3.14.2 MEMORY MIRROR .........................................29
3.15 OVERHEAD CONSOLE .............................................29
3.15.1 VEHICLE INFORMATION DISPLAY............................30
3.15.2 TRAVELER DISPLAY FUNCTIONS ............................31
3.15.3 SETTING MAGNETIC ZONE VARIANCE .......................31
3.15.4 COMPASS CALIBRATION ...................................32
3.15.5 SELF-CHECK DIAGNOSTICS ................................32
3.15.6 AMBIENT TEMPERATURE SENSOR ..........................32
3.15.7 AMBIENT TEMPERATURE SENSOR FAULT CODES .............33
3.15.8 HOMELINKT UNIVERSAL TRANSMITTER ......................33
3.15.9 TIRE PRESSURE MONITORING SYSTEM (TPMS)...............33
3.15.9.1 TRAINING THE SKREEM....................................33
3.15.9.2 PRESSURE THRESHOLDS ..................................34
3.15.9.3 ACTIVE FAULT AND SYSTEM ALERTS ........................34
3.16 PARK ASSIST SYSTEM .............................................34
3.17 POWER DOOR LOCK SYSTEM ......................................34
3.17.1 DOOR LOCK INHIBIT .......................................34
3.17.2 AUTOMATIC DOOR LOCKS .................................35
3.17.3 REMOTE KEYLESS ENTRY (RKE) ............................35
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TABLE OF CONTENTS - Continued
3.17.3.1 PANIC FUNCTION .........................................35
3.17.3.2 ROLLING CODE ...........................................35
3.17.3.3 PROGRAMMABLE DOOR LOCK FEATURES ...................35
3.18 POWER FOLDING MIRRORS ........................................36
3.19 POWER LIFTGATE SYSTEM .........................................36
3.19.1 POWER LIFTGATE .........................................36
3.19.2 DIAGNOSTIC FEATURES ...................................36
3.19.3 SYSTEM INHIBITORS ......................................36
3.20 POWER SLIDING DOOR SYSTEM ....................................36
3.20.1 POWER SLIDING DOOR ....................................36
3.20.2 DIAGNOSTIC FEATURES ...................................37
3.20.3 SYSTEM INHIBITORS ......................................37
3.21 REAR WINDOW DEFOG/HEATED MIRROR/FRONT WIPER DE-ICE (IF
EQUIPPED) .......................................................37
3.22 TELECOMMUNICATIONS ...........................................37
3.22.1 HANDS FREE PHONE ......................................37
3.23 VEHICLE THEFT SECURITY SYSTEM .................................38
3.23.1 THATCHAM ALARM SYSTEM (EXPORT ONLY) .................38
3.24 WIPER SYSTEM ...................................................38
3.24.1 FRONT WIPER ............................................38
3.24.2 SPEED SENSITIVE INTERMITTENT WIPE MODE ...............39
3.24.3 PULSE WIPE ..............................................39
3.24.4 PARK AFTER IGNITION OFF.................................39
3.24.5 WIPE AFTER WASH ........................................39
3.24.6 REAR WIPER .............................................39
3.24.7 SPEED SENSITIVE INTERMITTENT WIPE MODE ...............39
3.24.8 WIPE AFTER WASH ........................................39
3.25 USING THE DRBIIIT ................................................39
3.26 DRBIIIT ERROR MESSAGES ........................................39
3.27 DRBIIIT DOES NOT POWER UP (BLANK SCREEN)......................39
3.28 DISPLAY IS NOT VISIBLE ...........................................39
4.0 DISCLAIMERS, SAFETY, WARNINGS ......................................40
4.1 DISCLAIMERS.....................................................40
4.2 SAFETY ..........................................................40
4.2.1 TECHNICIAN SAFETY INFORMATION .........................40
4.2.2 VEHICLE PREPARATION FOR TESTING .......................40
4.2.3 SERVICING SUB-ASSEMBLIES ..............................40
4.2.4 DRBIIIT SAFETY INFORMATION .............................40
4.3 WARNINGS .......................................................41
4.3.1 VEHICLE DAMAGE WARNINGS ..............................41
4.3.2 ROAD TESTING A COMPLAINT VEHICLE......................41
5.0 REQUIRED TOOLS AND EQUIPMENT .....................................41
6.0 GLOSSARY OF TERMS..................................................41
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TABLE OF CONTENTS - Continued
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ..........................43
ADJUSTABLE PEDALS
PEDAL SENSOR OPEN/SHORTED TO GROUND.............................44
PEDAL SENSOR SHORTED TO BATTERY ..................................47
PEDAL SW STUCK FORWARD ............................................50
PEDAL SW STUCK REARWARD ..........................................52
*CAN’T ADJUST PEDALS ................................................54
*CAN’T SET/RECALL MEMORY POSITIONS .................................59
AIRBAG
ACCELEROMETER 1 ....................................................61
ACCELEROMETER 2 ....................................................61
INTERNAL 1 ...........................................................61
INTERNAL 2 ...........................................................61
INTERNAL 3 ...........................................................61
INTERNAL 4 ...........................................................61
MODULE NOT CONFIGURED FOR OCS ....................................61
OUTPUT DRIVER 1 .....................................................61
OUTPUT DRIVER 2 .....................................................61
STORED ENERGY FIRING 1..............................................61
AIRBAG WARNING INDICATOR OPEN .....................................64
AIRBAG WARNING INDICATOR SHORT ....................................64
CALIBRATION MISMATCH................................................67
CLUSTER MESSAGE MISMATCH .........................................69
DRIVER KNEE BLOCKER CIRCUIT OPEN ..................................71
DRIVER KNEE BLOCKER CIRCUIT SHORT .................................74
DRIVER KNEE BLOCKER SHORT TO BATTERY .............................77
DRIVER KNEE BLOCKER SHORT TO GROUND .............................80
DRIVER SEAT BELT SWITCH CIRCUIT OPEN ...............................83
DRIVER SEAT BELT SWITCH SHORTTO BATTERY ..........................86
DRIVER SEAT BELT SWITCH SHORT TO GROUND ..........................89
DRIVER SEAT BELT SWITCH SHORT TOGETHER ...........................91
DRIVER SEAT BELT TENSIONER CIRCUIT OPEN ............................93
DRIVER SEAT BELT TENSIONER CIRCUIT SHORT ..........................96
DRIVER SEAT BELT TENSIONER SHORT TO BATTERY.......................99
DRIVER SEAT BELT TENSIONER SHORT TO GROUND ......................102
DRIVER SQUIB 1 CIRCUIT OPEN ........................................105
DRIVER SQUIB 1 CIRCUIT SHORT .......................................108
DRIVER SQUIB 1 SHORT TO BATTERY ...................................111
DRIVER SQUIB 1 SHORT TO GROUND ...................................114
DRIVER SQUIB 2 CIRCUIT OPEN ........................................117
DRIVER SQUIB 2 CIRCUIT SHORT .......................................120
DRIVER SQUIB 2 SHORT TO BATTERY ...................................123
DRIVER SQUIB 2 SHORT TO GROUND ...................................126
INTERROGATE OCM ...................................................129
LEFT CURTAIN OR SEAT SQUIB CIRCUIT OPEN ...........................131
LEFT CURTAIN OR SEAT SQUIB CIRCUIT SHORT ..........................134
LEFT CURTAIN OR SEAT SQUIB SHORTTO BATTERY ......................137
LEFT CURTAIN OR SEAT SQUIB SHORT TO GROUND ......................140
LEFT FRONT IMPACT SENSOR INTERNAL 1 ...............................143
NO LEFT FRONT IMPACT SENSOR COMMUNICATION ......................143
LEFT SIDE IMPACT SENSOR 1 INTERNAL 1 ...............................147
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TABLE OF CONTENTS - Continued
NO LEFT SIDE IMPACT SENSOR 1 COMMUNICATION.......................147
LEFT SIDE IMPACT SENSOR 2 INTERNAL 1 ...............................151
NO LEFT SIDE IMPACT SENSOR 2 COMMUNICATION.......................151
LEFT SIDE IMPACT SENSOR 3 INTERNAL 1 ...............................155
NO LEFT SIDE IMPACT SENSOR 3 COMMUNICATION.......................155
LOSS OF IGNITION RUN - START ........................................159
ORC RUN - START DRIVER OPEN .......................................159
ORC RUN - START DRIVER OVER CURRENT ..............................159
ORC RUN - START DRIVER OVER TEMP ..................................159
ORC RUN - START DRIVER OVER VOLT ..................................159
ORC RUN - START DRIVER SHORT TO GROUND ..........................159
LOSS OF IGNITION RUN ONLY ..........................................165
ORC RUN ONLY DRIVER OPEN..........................................165
ORC RUN ONLY DRIVER OVER CURRENT ................................165
ORC RUN ONLY DRIVER OVER TEMP ....................................165
ORC RUN ONLY DRIVER OVER VOLT ....................................165
ORC RUN ONLY DRIVER SHORT TO GROUND.............................165
NO CLUSTER MESSAGE ...............................................171
NO OCM MESSAGE ....................................................173
NO ODOMETER MESSAGE .............................................175
NO ORC MESSAGE ....................................................178
NO PCI LOOPBACK ....................................................181
PCI BUS SHORT TO BATTERY...........................................181
PCI BUS SHORT TO GROUND ...........................................181
NO PCI TRANSMISSION ................................................187
NO RIGHT FRONT IMPACT SENSOR COMMUNICATION .....................189
RIGHT FRONT IMPACT SENSOR INTERNAL 1 .............................189
NO RIGHT SIDE IMPACT SENSOR 1 COMMUNICATION .....................193
RIGHT SIDE IMPACT SENSOR 1 INTERNAL 1 ..............................193
NO RIGHT SIDE IMPACT SENSOR 2 COMMUNICATION .....................197
RIGHT SIDE IMPACT SENSOR 2 INTERNAL 1 ..............................197
NO RIGHT SIDE IMPACT SENSOR 3 COMMUNICATION .....................201
RIGHT SIDE IMPACT SENSOR 3 INTERNAL 1 ..............................201
OCCUPANT CLASSIFICATION MODULE DATATRANSFER ERROR ............205
OCCUPANT CLASSIFICATION UNDETERMINED ............................207
RE-ZERO INCOMPLETE ................................................207
SEAT NOT CALIBRATED ................................................207
SYSTEM VERIFICATION REQUIRED - OCSVR .............................207
OCM CONFIGURATION MISMATCH.......................................212
PASSENGERAIRBAG OFF INDICATOR CIRCUIT SHORT TO BATTERY ........214
PASSENGER AIRBAG OFF INDICATOR CIRCUIT SHORT TO GROUND.........217
PASSENGER BTS OPEN ................................................222
PASSENGER BTS SHORT TO BATTERY...................................222
PASSENGER BTS SHORT TO GROUND ...................................222
PASSENGER BTS SHORT TOGETHER ....................................222
PASSENGER PRESSURE SENSOR OPEN .................................226
PASSENGER PRESSURE SENSOR SHORT GROUND .......................226
PASSENGER PRESSURE SENSOR SHORT TO BATTERY ....................226
PASSENGER PRESSURE SENSOR SHORT TOGETHER .....................226
PASSENGER SEAT BELT SWITCH CIRCUIT OPEN ..........................229
PASSENGER SEAT BELT SWITCH SHORTTO BATTERY .....................231
PASSENGER SEAT BELT SWITCH SHORTTO GROUND .....................234
PASSENGER SEAT BELT SWITCH SHORT TOGETHER ......................237
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The 2004 CHRYSLER VOYAGER Service and Repair Manual is a comprehensive guide designed to assist owners and mechanics in maintaining and repairing their 2004 CHRYSLER VOYAGER models.
With this manual, you'll have access to detailed instructions and diagrams that will enable you to tackle a wide range of repairs and service tasks with confidence. Whether you need to perform routine maintenance or address more complex issues, this manual provides step-by-step guidance.
Here are some of the key features of the 2004 CHRYSLER VOYAGER Service and Repair Manual:
- Includes detailed information on the CHRYSLER VOYAGER models from the year 2004
- Covers a wide range of repairs and service tasks
- Provides step-by-step instructions and illustrations to assist in the maintenance process
- Contains valuable tips and recommendations from expert mechanics
- Allows you to save money by performing repairs yourself
- Ensures you have the necessary knowledge to keep your CHRYSLER VOYAGER in top condition
Whether you're a professional mechanic or a DIY enthusiast, the 2004 CHRYSLER VOYAGER Service and Repair Manual is an invaluable resource that will help you maintain and repair your vehicle with ease.
