1996 CHRYSLER VOYAGER wiring

(5) Verify that the electrical connector is attached
to the MAP sensor (Fig. 64).
(6) Check generator wiring connections. Ensure
the accessory drive belt has proper tension.
(7) Verify that hoses are securely attached to the
evaporative canister (Fig. 65).
(8) Verify the engine ground strap is attached at
the engine and dash panel (Fig. 66).
(9) Ensure the heated oxygen sensor connector is
connected to the harness connector.
(10) Verify the distributor connector is connected
to the harness connector (Fig. 67).
(11) Verify the coolant temperature sensor connec-
tor is connected to the harness connector (Fig. 68).(12) Check vacuum hose connection at fuel pres-
sure regulator and intake plenum connector (Fig. 68).
Fig. 64 Map Sensor Electrical and Vacuum
Connections
Fig. 65 Evaporative Canister
Fig. 66 Engine Ground Strap
Fig. 67 Distributor Connector
Fig. 68 Coolant Temperature Sensor Electrical
Connections and Vacuum Hose Connections at the
Air Intake Plenum
NSFUEL SYSTEM 14 - 53
DIAGNOSIS AND TESTING (Continued)

terminals. Verify the connectors are fully inserted
into the socket of the PCM (Fig. 74). Ensure that
wires are not stretched or pulled out of the connector.
(24) Inspect fuses in the Power Distribution Cen-
ter (PDC). Verify all fuses and relays are fully
inserted into the PDC (Fig. 74). A label affixed to the
underside of the PDC cover identifies the relays and
fuses in the PDC.
(25) Check Battery Cable Connections.
(26) Check hose and wiring connections at fuel
pump module. Check that wiring connector is making
contact with terminals on pump.
VISUAL INSPECTIONÐ3.3/3.8L ENGINES
A visual inspection for loose, disconnected, or mis-
routed wires and hoses should be made before
attempting to diagnose or service the fuel injection
system. A visual check helps save unnecessary test
and diagnostic time. A thorough visual inspection will
include the following checks:
(1) Check ignition cable routing from the coil pack
to the spark plugs. Verify the cable are routed in the
correct order and are fully seated to the coil and
spark plug.(2) Check direct ignition system (DIS) coil electri-
cal connection for damage and a complete connection
to the coil pack (Fig. 75).
(3) Verify the camshaft position sensor electrical
connector is connected to the harness and not dam-
aged (Fig. 76).
(4) Ensure the engine temperature sensor electri-
cal connector is connected to the sensor and not dam-
aged (Fig. 77).
(5) Verify the quick connect fuel fitting is fully
inserted on the fuel supply tube.
(6) Check the oil pressure sending unit electrical
connection (Fig. 78).
Fig. 74 Powertrain Control Module (PCM)
Fig. 75 Ignition Coil Pack Electrical Connection
Fig. 76 Camshaft Position Sensor
NSFUEL SYSTEM 14 - 55
DIAGNOSIS AND TESTING (Continued)

(7) Verify the electrical connector at the knock sen-
sor is fully seated and not damaged (Fig. 78).
(8) Verify the electrical connector is attached to
the Proportional purge solenoid (Fig. 79) and not
damaged.
(9) Verify the vacuum connection at the Propor-
tional purge solenoid is secure and not leaking (Fig.
79).(10) Verify the hoses are securely attached to the
EVAP canister (Fig. 80).
(11) Ensure the harness connectors for the fuel
injectors are attached to the correct injector and not
damaged.
(12) Verify the fuel injector harness and engine
wiring harness connectors are fully inserted into the
main wiring harness.
Fig. 77 Engine Coolant Temperature Sensor
Fig. 78 Knock Sensor and Oil Pressure Sending
Unit Electrical Connection
Fig. 79 Proportional Purge Solenoid
Fig. 80 Evaporative Canister
14 - 56 FUEL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

(13) Check the vacuum connections at the throttle
body and intake plenum (Fig. 81).
(14) Ensure the idle air control motor and TPS
electrical connectors are fully seated and not dam-
aged (Fig. 82).
(15) Inspect the park/neutral switch wiring connec-
tion for damage. Ensure the automatic transaxle
electrical connections are not damaged (Fig. 83).(16) Inspect the PCV system connections for dam-
age (Fig. 84).
(17) Inspect the crankshaft position sensor electri-
cal connector for damage (Fig. 85).
(18) Verify the Manifold Absolute Pressure (MAP)
sensor electrical connector is attached to the sensor
and not damaged (Fig. 86).
Fig. 81 Throttle Body Vacuum Connections
Fig. 82 Throttle Body Electrical Connections
Fig. 83 Automatic Transaxle Electrical Connections
Fig. 84 PCV Valve and Fresh Air Hose
NSFUEL SYSTEM 14 - 57
DIAGNOSIS AND TESTING (Continued)

(19) Check the heated oxygen sensor electrical con-
nectors for damage (Fig. 87) and (Fig. 88).(20) Verify the engine ground strap is attached at
the engine and dash panel. Inspect the strap for cor-
rosion or damage.
(21) Inspect the generator wiring connections for
damage.
(22) Check the accessory drive belt tension.
(23) Check the 40-way electrical connectors at the
Powertrain Control Module (PCM) (Fig. 89) for dam-
age or spread terminals. Verify that the connectors
are fully inserted into the PCM sockets. Ensure the
wires are not stretched or pulled out of the connector.
(24) Inspect fuses in the Power Distribution Cen-
ter (PDC). Verify all fuses and relays are fully
Fig. 85 Crankshaft Position Sensor
Fig. 86 MAP Sensor
Fig. 87 Upstream Heated Oxygen Sensor
Fig. 88 Downstream Heated Oxygen Sensor
Fig. 89 Powertrain Control Module (PCM)
Connectors
14 - 58 FUEL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

inserted into the PDC (Fig. 90). A label affixed to the
underside of the PDC cover identifies the relays and
fuses in the PDC.
(25) Inspect battery cable connections for corro-
sion.
(26) Check the power brake booster hose connec-
tion (without anti-lock brake systems) (Fig. 91).
(27) Inspect the speed control vacuum connection
(Fig. 92).(28) Inspect hose and wiring connections at fuel
pump module. Check that wiring connector is making
contact with terminals on pump.
ASD AND FUEL PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The terminals on the
bottom of each relay are numbered (Fig. 93) or (Fig.
94).
OPERATION
²Terminal number 30 is connected to battery volt-
age. For both the ASD and fuel pump relays, termi-
nal 30 is connected to battery voltage at all times.
Fig. 90 Power Distribution Center (PDC)
Fig. 91 Power Brake Booster Hose
Fig. 92 Speed Control Vacuum
Fig. 93 ASD and Fuel Pump Relay Terminals
NSFUEL SYSTEM 14 - 59
DIAGNOSIS AND TESTING (Continued)

PCM. If OK, replace MAP sensor. If not OK, repair or
replace the wire harness as required.
HEATED OXYGEN SENSOR
Use an ohmmeter to test the heating element of
the oxygen sensors. Disconnect the electrical connec-
tor from each oxygen sensor. The white wires in the
sensor connector are the power and ground circuits
for the heater. Connect the ohmmeter test leads to
terminals of the white wires in the heated oxygen
sensor connector. Replace the heated oxygen sensor if
the resistance is not between 4 and 7 ohms.
KNOCK SENSOR
The engine knock sensor is affected by a number of
factors. A few of these are: ignition timing, cylinder
pressure, fuel octane, etc. The knock sensor gener-
ates an AC voltage whose amplitude increases with
the increase of engine knock. The knock sensor can
be tested with a digital voltmeter. The RMS voltage
starts at about 20mVac (at about 700 rpm) and
increases to approximately 600 mVac (5000 rpm). If
the output falls outside of this range a DTC will be
set.
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
Refer to Group 8D, Ignition for Diagnosis and Test-
ing of Camshaft and Crankshaft Sensors.
ENGINE COOLANT TEMPERATURE SENSOR
(1) With the key off, disconnect wire harness con-
nector from coolant temperature sensor (Fig. 96) or
(Fig. 97) or (Fig. 98).
(2) Connect a high input impedance (digital) volt-
ohmmeter to terminals A and B (Fig. 99). The ohm-
meter should read as follows:
(a) ECT STET at normal operating temperature
around 200ÉF should read approximately 700 to
1,000 ohms.
(b) ECT STET at room temperature around 70ÉF
ohmmeter should read approximately 7,000 to
13,000 ohms.
(3) Test the resistance of the wire harness between
the PCM connector terminal 26 and the sensor har-
ness connector. Also check for continuity between
PCM connector terminal 43 and the sensor harness
connector. Refer to Group 8W, Wiring diagrams for
Fig. 96 Engine Coolant Temperature SensorÐ2.4L
Fig. 97 Engine Coolant Temperature SensorÐ3.0L
Fig. 98 Engine Coolant Temperature SensorÐ3.3/
3.8L
NSFUEL SYSTEM 14 - 61
DIAGNOSIS AND TESTING (Continued)

circuit information. If the resistance is greater than 1
ohm, repair the wire harness as necessary.
THROTTLE POSITION SENSOR
To perform a complete test of the this sensor and
its circuitry, refer to the DRB scan tool and appropri-
ate Powertrain Diagnostics Procedures manual. To
test the throttle position sensor only, refer to the fol-
lowing:
The Throttle Position Sensor (TPS) can be tested
with a digital voltmeter (DVM). The center terminal
of the sensor is the output terminal. One of the other
terminals is a 5 volt supply and the remaining ter-
minal is ground.
Connect the DVM between the center and sensor
ground terminal. Refer to Group 8W - Wiring Dia-
grams for correct pinout.
With the ignition switch in the ON position, check
the output voltage at the center terminal wire of the
connector. Check the output voltage at idle and at
Wide-Open-Throttle (WOT). At idle, TPS output volt-
age should be approximately 0.38 volts to 1.2 volts.
At wide open throttle, TPS output voltage should be
approximately 3.1 volts to 4.4 volts. The output volt-
age should gradually increase as the throttle plate
moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM
connections before replacing the TPS.
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
(1) Warm engine in Park or Neutral until the cool-
ing fan has cycled on and off at least once.
(2) Ensure that all accessories are off.
(3) Shut off engine.
(4)3.0L Engine
(a) Hook-up the timing check device and tachom-
eter.(b) Disconnect the engine coolant temperature
sensor and set basic timing to 12É BTDC62É.
(c) Shut off engine. Reconnect coolant tempera-
ture sensor wire.
(5) Disconnect the PCV valve hose from the intake
manifold nipple (Fig. 101), (Fig. 102) or (Fig. 103).
(6) Cap the PCV valve nipple.
(7)3.3/3.8L Engines
(a) Install Air Metering Fitting 6457 (0.125 in.
orifice) to the intake manifold PCV nipple (Fig.
100).
(b) Disconnect the idle purge line from the throt-
tle body nipple.
(8)3.0/2.4L Engines
(a) Install Air Metering Fitting 6457 (0.125 in.
orifice) to the purge nipple on the throttle body.
(9)3.3/3.8L Engines
(a) Cap the 3/16 inch nipple.
(b) Connect the DRB scan tool to the data link
connector.
(10) Restart the engine. Allow engine to idle until
the cooling fan has cycled on and off at least one
180ÉF cycle.
(11) Using the DRB scan tool, access the Minimum
Airflow Idle Speed screen.
(12) The following will then occur:
²Idle air control motor will fully close.
²Idle spark advance will become fixed.
²DRB scan tool displays engine rpm.
(13) If idle rpm is within the range shown in the
Idle Specification chart, throttle body minimum air-
flow is set correctly.
IDLE SPECIFICATIONSÐ2.4L ENGINE
Odometer Reading Idle RPM
Below 1000 Miles.................500-875 RPM
Above 1000 Miles.................550±875 RPM
Fig. 99 Engine Coolant Temperature Sensor
Fig. 100 Air Metering Fitting 6457
14 - 62 FUEL SYSTEMNS
DIAGNOSIS AND TESTING (Continued)