1996 CHRYSLER VOYAGER torque

plugs.Ash encrusted spark plugs can be cleaned
and reused.
HIGH SPEED MISS
When replacing spark plugs because of a high
speed miss condition;wide open throttle opera-
tion should be avoided for approximately 80 km
(50 miles) after installation of new plugs.This
will allow deposit shifting in the combustion chamber
to take place gradually and avoid plug destroying
splash fouling shortly after the plug change.
ELECTRODE GAP BRIDGING
Loose deposits in the combustion chamber can
cause electrode gap bridging. The deposits accumu-
late on the spark plugs during continuous stop-
and-go driving. When the engine is suddenly
subjected to a high torque load, the deposits partially
liquefy and bridge the gap between the electrodes
(Fig. 25). This short circuits the electrodes.Spark
plugs with electrode gap bridging can be
cleaned and reused.
SCAVENGER DEPOSITS
Fuel scavenger deposits may be either white or yel-
low (Fig. 26). They may appear to be harmful, but
are a normal condition caused by chemical additives
in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease
spark plug misfire tendencies. Notice that accumula-
tion on the ground electrode and shell area may be
heavy but the deposits are easily removed.Spark
plugs with scavenger deposits can be consid-
ered normal in condition, cleaned and reused.
CHIPPED ELECTRODE INSULATOR
A chipped electrode insulator usually results from
bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions,
severe detonation also can separate the insulator
from the center electrode (Fig. 27).Spark plugs
with chipped electrode insulators must be
replaced.
PREIGNITION DAMAGE
Excessive combustion chamber temperature can
cause preignition damage. First, the center electrode
dissolves and the ground electrode dissolves some-
what later (Fig. 28). Insulators appear relatively
deposit free. Determine if the spark plugs are the
correct type, as specified on the VECI label, or if
other operating conditions are causing engine over-
heating.
SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center
electrode insulator that also appears blistered (Fig.
Fig. 24 Oil or Ash Encrusted
Fig. 25 Electrode Gap Bridging
Fig. 26 Scavenger Deposits
8D - 12 IGNITION SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

2.4L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
CAMSHAFT POSITION SENSOR............ 17
CRANKSHAFT POSITION SENSOR.......... 16
FIRING ORDERÐ2.4L.................... 16
INTAKE AIR TEMPERATURE SENSORÐ2.4L . . . 17
REMOVAL AND INSTALLATION
CAMSHAFT POSITION SENSOR............ 19
CRANKSHAFT POSITION SENSOR.......... 19
ENGINE COOLANT TEMPERATURE SENSORÐ
2.4L................................. 20
IGNITION COILÐ2.4L..................... 18
INTAKE AIR TEMPERATURE SENSORÐ2.4L . . . 21KNOCK SENSORÐ2.4L................... 21
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ2.4/3.3/3.8L.................. 20
SPARK PLUG CABLE SERVICEÐ2.4L........ 18
SPARK PLUG SERVICE................... 18
THROTTLE POSITION SENSOR............ 20
SPECIFICATIONS
IGNITION COIL......................... 22
SPARK PLUG CABLE RESISTANCEÐ2.4L..... 22
SPARK PLUG........................... 22
TORQUE.............................. 22
DESCRIPTION AND OPERATION
FIRING ORDERÐ2.4L
CRANKSHAFT POSITION SENSOR
The PCM determines what cylinder to fire from the
crankshaft position sensor input and the camshaft
position sensor input. The second crankshaft counter-
weight has machined into it two sets of four timing
reference notches and a 60 degree signature notch
(Fig. 1). From the crankshaft position sensor input
the PCM determines engine speed and crankshaft
angle (position).The notches generate pulses from high to low in
the crankshaft position sensor output voltage. When
a metal portion of the counterweight aligns with the
crankshaft position sensor, the sensor output voltage
goes low (less than 0.3 volts). When a notch aligns
with the sensor, voltage switches high (5.0 volts). As
a group of notches pass under the sensor, the output
voltage switches from low (metal) to high (notch)
then back to low.
If available, an oscilloscope can display the square
wave patterns of each voltage pulse. From the width
of the output voltage pulses, the PCM calculates
engine speed. The width of the pulses represent the
amount of time the output voltage stays high before
switching back to low. The period of time the sensor
output voltage stays high before switching back to
low is referred to as pulse width. The faster the
FIRING ORDERÐ2.4L
Fig. 1 Timing Reference Notches
8D - 16 IGNITION SYSTEMNS

REMOVAL AND INSTALLATION
SPARK PLUG CABLE SERVICEÐ2.4L
The cables insulate the spark plugs and covers the
top of the spark plug tube (Fig. 6). To remove the
cables, lightly grasp the top of the cable. Rotate the
insulator 90É and pull straight up. To replace the
cables, disconnect the cable from the ignition coil.
Ensure the #1 and #4 cables run under the #2
and #3 ignition coil towers. Keep #4 cable away
from the oil fill cap.
SPARK PLUG SERVICE
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them inthe appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs orshort cir-
cuit the cables to ground.
Never Wire Brush Spark Plugs.The spark plug
insulator tip is harder than the bristles of wire
brushes. Bristles of wire brushes can leave a conduc-
tive, metallic film on the insulator which could lead
to conductive deposits. Conductive deposits can cause
spark plug failure and engine misfire. Use a jewelers
file to remove deposits from the electrode gap or use
a spark plug cleaning machine to clean spark plugs.
REMOVAL
Always remove cables by grasping at the boot,
rotating the boot 1/2 turn, and pulling straight back
in a steady motion.
(1) Prior to removing the spark plug, spray com-
pressed air around the spark plug hole and the area
around the spark plug.
(2) Remove the spark plug using a quality socket
with a foam insert.
(3) Inspect the spark plug condition. Refer to
Spark Plug Condition in this section.
INSTALLATION
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 N´m (20 ft. lbs.)
torque.
(3) Install spark plug cables over spark plugs. A
click will be heard and felt when the cable properly
attaches to the spark plug.
IGNITION COILÐ2.4L
REMOVAL
REMOVAL
(1) Remove spark plug cables from coil (Fig. 7).
Always twist the coil boots to break the seal with the
coil and pull straight back on the boot.
(2) Remove ignition coil electrical connector.
(3) Remove ignition coil mounting bolts, throttle
cable bracket or clip.
(4) Remove ignition coil.
INSTALLATION
(1) Reverse the above procedure for installation.
Tighten mounting screws to 12 N´m (105 in. lbs.)
torque.
(2) Transfer ignition cables to new coil pack. The
coil pack towers and cables are numbered with cylin-
der identification.
Fig. 5 Intake Air Temperature Sensor
Fig. 6 Spark Plug Cables
8D - 18 IGNITION SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

CRANKSHAFT POSITION SENSOR
The crankshaft position sensor mounts to the
engine block behind the generator, just behind the oil
filter (Fig. 8).
REMOVAL
(1) Raise and support vehicle.
(2) Disconnect electrical connector from crankshaft
position sensor.
(3) Remove sensor mounting screw.
(4) Pull crankshaft position sensor straight out.
INSTALLATION
NOTE: If the removed sensor is to be reinstalled,
clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the sensor face before
installation. If the sensor is being replaced, confirm
that the paper spacer is attached to the face of the
new sensor.
(1) Install sensor and push sensor down until con-
tact is made. While holding the sensor in this posi-
tion, and install and tighten the retaining bolt to 11.9
N´m (105 in. lbs.) torque.
CAMSHAFT POSITION SENSOR
The camshaft position sensor is mounted to the
rear of the cylinder head (Fig. 9).
REMOVAL
(1) Disconnect the filtered air tube from the throt-
tle body and air cleaner housing. Disconnect the airtube from the oil separator hose. Remove filtered air
tube.
(2) Remove the air cleaner inlet tube.
(3) Disconnect engine harness connector from cam-
shaft position sensor.
(4) Remove camshaft position sensor mounting
screws. Remove sensor.
(5) Loosen screw attaching target magnet to rear
of camshaft (Fig. 10).
INSTALLATION
The target magnet has locating dowels that fit into
off-set machined locating holes in end of the cam-
shaft (Fig. 11).
Fig. 7 Ignition Coil RemovalFig. 8 Crankshaft Position Sensor
Fig. 9 Camshaft Position Sensor Location
NSIGNITION SYSTEM 8D - 19
REMOVAL AND INSTALLATION (Continued)

(1) Install target magnet in end of camshaft.
Tighten mounting screw to 5.65 N´m (50 in. lbs.)
torque.
(2) Install a new O-ring on sensor.
(3) Install camshaft position sensor. Tighten sensor
mounting screws to 9.6 N´m (85 in. lbs.) torque.
(4) Attach engine harness connector to camshaft
position sensor.
(5) Install air cleaner inlet tube and filtered air
tube.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ2.4/3.3/3.8L
REMOVAL
(1) Disconnect electrical connector from MAP sen-
sor (Fig. 12).
(2) Remove two screws holding sensor to the
intake manifold.
INSTALLATION
(1) Reverse the above procedure for installation.
THROTTLE POSITION SENSOR
Refer to Group 14, Fuel Injection Section, for
Removal/Installation.
ENGINE COOLANT TEMPERATURE SENSORÐ2.4L
The coolant sensor threads into the top of the ther-
mostat housing (Fig. 13). New sensors have sealant
applied to the threads.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7- COOLING.
Fig. 10 Target Magnet
Fig. 11 Target Magnet Installation
Fig. 12 Map Absolute Pressure Sensor
Fig. 13 Engine Coolant Temperature SensorÐ2.4L
8D - 20 IGNITION SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head. Refer to Group 7, Cooling
System.
(2) Disconnect coolant sensor electrical connector.
(3) Remove coolant sensor.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 7 N´m
(60 in. lbs.) torque.
(2) Attach electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
KNOCK SENSORÐ2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 14).
REMOVAL
(1) Disconnect electrical connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensors.
INSTALLATION
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
INTAKE AIR TEMPERATURE SENSORÐ2.4L
The intake air temperature sensor threads into the
intake manifold plenum (Fig. 15).
REMOVAL
(1) Remove electrical connector from sensor.
(2) Remove sensor.
INSTALLATION
(1) Install sensor. Tighten sensor to 28 N´m (20 ft.
lbs.) torque.
(2) Attach electrical connector to sensor.
Fig. 14 Knock Sensor
Fig. 15 Intake Air Temperature Sensor
NSIGNITION SYSTEM 8D - 21
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
IGNITION COIL
SPARK PLUG
TORQUE
DESCRIPTION......................TORQUE
2.4L Target Magnet Screw.......3N´m(30in.lbs.)
2.4L Camshaft Position Sensoe Screw . .9 N´m (80 in.
lbs.)
Ignition Switch...............2N´m(17in.lbs.)
Spark Plugs.................28N´m(60in.lbs.)
SPARK PLUG CABLE RESISTANCEÐ2.4L
Coil ManufacturePrimary Resistance at 21ÉC-27ÉC
(70ÉF-80ÉF)Secondary Resistance at 21ÉC-
27ÉC (70ÉF-80ÉF)
Weastec (Steel Towers) 0.45 to 0.65 Ohms 7,000 to 15,800 Ohms
Coil Polarity
Engine Spark Plug Gap Thread Size
2.4L RC12YC5 0.048 TO 0.053 14mm (3/4 in.) reach
CABLE Maximum
Resistance
#1 & #4 4.2K ohms
#2 & #3 3.2K ohms
8D - 22 IGNITION SYSTEMNS

3.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
CAMSHAFT POSITION SENSOR............ 23
FIRING ORDERÐ3.0L.................... 23
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR............................. 23
REMOVAL AND INSTALLATION
CRANKSHAFT POSITION SENSOR.......... 25
ENGINE COOLANT TEMPERATURE SENSORÐ
3.0L................................. 25
IGNITION COILÐ3.OL.................... 24
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ3.0L........................ 24SPARK PLUG SERVICE................... 24
THROTTLE POSITION SENSOR............ 25
DISASSEMBLY AND ASSEMBLY
DISTRIBUTORÐ3.0L..................... 26
CLEANING AND INSPECTION
DISTRIBUTOR CAP...................... 26
DISTRIBUTOR ROTORÐ3.0L............... 27
SPECIFICATIONS
SPARK PLUG CABLE RESISTANCEÐ3.0L..... 27
SPARK PLUG........................... 27
TORQUE.............................. 27
DESCRIPTION AND OPERATION
FIRING ORDERÐ3.0L
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The MAP sensor reacts to absolute pressure in the
intake manifold and provides an input voltage to the
Powertrain Control Module (PCM). As engine load
changes, manifold pressure varies. The changes in
engine load cause the MAP sensors resistance to
change. The change in MAP sensor resistance results
in a different input voltage to the PCM.
The input voltage level supplies the PCM with
information relating to ambient barometric pressure
during engine start-up (cranking) and engine load
while its operating. Based on MAP sensor voltage
and inputs from other sensors, the PCM adjusts
spark advance and the air-fuel mixture.
CAMSHAFT POSITION SENSOR
The PCM determines fuel injection synchronization
and cylinder identification from inputs provided by
the camshaft position sensor and crankshaft position
sensor. From the two inputs, the PCM determines
crankshaft position.
The 3.0L engine is equipped with a camshaft
driven mechanical distributor, containing a shaft
driven distributor rotor. The distributor is also
equipped with an internal camshaft position (fuel
sync) sensor (Fig. 1). This sensor provides fuel injec-
tion synchronization and cylinder identification to
the PCM.
The camshaft position sensor contains a hall effect
device callled a sync signal generator. This sync sig-
nal generator detects a rotating pulse ring (shutter)
on the distributor shaft. The pulse ring rotates 180
through the sync signal generator. Its signal is used
in conjunction with the crankshaft position sensor to
differentiate between fuel injection and spark events.
It is also used to synchronize the fuel injectors with
their respective cylinders.
When the leading edge of the shutter enters the
sync signal generator, the interruption of magnetic
field causes the voltage to switch high. This causes a
sync signal of approximately 5 volts.
When the trailing edge of the shutter leaves the
sync signal generator, the change of magnetic field
causes the sync signal voltage to switch low to 0
volts.
Since the shutter rotates at half crankshaft speed,
it may take 1 engine revolution during cranking for
the PCM to determine the position of piston number
6.
SPARK PLUG WIRE ROUTINGÐ3.0L ENGINE
NSIGNITION SYSTEM 8D - 23