1996 CHRYSLER VOYAGER engine

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

REMOVAL AND INSTALLATION
SPARK PLUG SERVICE
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them in
the 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 COILÐ3.OL
The ignition coil is located at the back of the
intake manifold (Fig. 2).
REMOVAL
(1) Remove air cleaner assembly.
(2) Disconnect ignition cable from coil.
(3) Disconnect wiring harness connector from coil.
(4) Remove coil mounting screws.
INSTALLATION
(1) Loosely install ignition coil on intake manifold.
Tighten the intake manifold fastener to 13 N´m (115
in. lbs.) torque. Tighten ignition coil bracket fasten-
ers to 10 N´m (96 in. lbs.) torque.
(2) Connect the wiring harness connector.
(3) Connect the coil to distributor ignition cable.
(4) Install the air cleaner assembly. Tighten the
air cleaner fasteners to 25 N´m (225 in. lbs.) torque.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ3.0L
REMOVAL
(1) Remove vacuum hose and mounting screws
from manifold absolute pressure (MAP) sensor (Fig.
3).
(2) Disconnect electrical connector from sensor.
Remove sensor.
Fig. 1 Camshaft Position SensorÐ3.0L Engine
Fig. 2 Ignition CoilÐ3.0L Engine
8D - 24 IGNITION SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

INSTALLATION
(1) Reverse the above procedure for installation.
ENGINE COOLANT TEMPERATURE SENSORÐ3.0L
The sensor is installed next to the thermostat
housing (Fig. 3).
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.
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.
CRANKSHAFT POSITION SENSOR
REMOVAL
(1) Raise and support vehicle.
(2) Disconnect crankshaft position sensor electrical
connector from the wiring harness connector (Fig. 4).
(3) Remove crankshaft position sensor retaining
bolt.
(4) Pull crankshaft position sensor straight up out
of the transaxle housing.
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 (Fig. 5).
(1) Install sensor in transaxle and push sensor
down until contact is made with the drive plate.
While holding the sensor in this position, and install
and tighten the retaining bolt to 11.9 N´m (105 in.
lbs.) torque.
(2) Raise and support vehicle.
(3) Connect crankshaft position sensor electrical
connector to the wiring harness connector.
THROTTLE POSITION SENSOR
Refer to Group 14, Fuel Injection Section, for
Removal/Installation.
Fig. 3 Manifold Absolute Pressure Sensor
Fig. 4 Crankshaft Position Sensor Connector
Fig. 5 Crankshaft Position Sensor and Spacer
NSIGNITION SYSTEM 8D - 25
REMOVAL AND INSTALLATION (Continued)

DISASSEMBLY AND ASSEMBLY
DISTRIBUTORÐ3.0L
REMOVAL
(1) Disconnect distributor connector from distribu-
tor (Fig. 6).
(2) Loosen distributor cap retaining screws.
(3) Lift cap of off distributor.
(4) Rotate engine crankshaft until the distributor
rotor points to the intake manifold plenum. Scribe a
mark on the plenum in line with the rotor. The scribe
line indicates where to position the rotor when rein-
stalling the distributor.
(5) Remove distributor hold down nut (Fig. 7).
(6) Carefully lift the distributor from the engine.
INSTALLATION
(1) Position distributor in engine. Make certain
that the O-ring is properly seated on distributor. If
O-ring is cracked or nicked replace with new one.
(2) Carefully engage distributor drive with gear on
camshaft. When the distributor is installed properly,
the rotor will be in line with previously scribe line on
air intake plenum.If engine was cranked while
distributor was removed, it will be necessary to
establish proper relationship between the dis-
tributor shaft and Number 1 piston position as
follows:
(a) Rotate the crankshaft until number one pis-
ton is at top of compression stroke.
(b) Rotate rotor to number one rotor terminal
(Fig. 8).
(c) Lower the distributor into the opening,
engaging distributor drive with drive on camshaft.
With distributor fully seated on engine, rotor
should be under the number 1 terminal.
(3) Install the distributor cap. Ensure sure all high
tension wires are firmly in the cap towers.
(4) Install hold-down nut and tighten (Fig. 7).
(5) Connect distributor electrical connector to dis-
tributor (Fig. 6).
CLEANING AND INSPECTION
DISTRIBUTOR CAP
Remove the distributor cap and inspect the inside
for flashover, cracking of carbon button, lack of
spring tension on carbon button, cracking of cap, and
burned, worn terminals (Fig. 9). Also check for bro-
ken distributor cap towers. If any of these conditions
are present the distributor cap and/or cables should
be replaced.
Fig. 6 Distributor Electrical ConnectorÐ3.0L Engine
Fig. 7 Distributor Hold-Down
Fig. 8 Distributor Cap Terminal Routing, View from
TopofCap
8D - 26 IGNITION SYSTEMNS