1996 CHRYSLER VOYAGER key

IGNITION SYSTEM
CONTENTS
page page
GENERAL INFORMATION................... 1
2.4L ENGINE............................ 16
3.0L ENGINE............................ 233.3/3.8L ENGINE........................ 28
IGNITION SWITCH AND LOCK CYLINDER..... 35
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
AUTOMATIC SHUTDOWN (ASD) RELAY....... 4
CAMSHAFT POSITION SENSOR............. 5
CRANKSHAFT POSITION SENSOR........... 5
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR.............................. 6
IGNITION COIL.......................... 4
IGNITION SYSTEM....................... 2
INTRODUCTION......................... 1
KNOCK SENSOR......................... 7
LOCK KEY CYLINDER..................... 7
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR.............................. 6
POWERTRAIN CONTROL MODULE........... 1
SPARK PLUG CABLE...................... 3
SPARK PLUGSÐ2.4/3.0L................... 2
SPARK PLUGSÐ3.3/3.8L................... 2
THROTTLE POSITION SENSOR (TPS)........ 7DIAGNOSIS AND TESTING
CAMSHAFT POSITION SENSOR AND
CRANKSHAFT POSITION SENSOR......... 11
CHECK COIL TESTÐ2.4L.................. 9
CHECK COIL TESTÐ3.3/3.8L................ 9
ENGINE COOLANT TEMPERATURE SENSOR . . 11
FAILURE TO START TEST................. 10
IGNITION TIMING PROCEDURE............ 11
INTAKE AIR TEMPERATURE SENSOR........ 11
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR TEST........................ 11
SPARK PLUG CONDITION................. 11
TESTING FOR SPARK AT COILÐ2.4/3.3/3.8L
ENGINES............................. 8
TESTING FOR SPARK AT COILÐ3.0L......... 8
THROTTLE POSITION SENSOR............ 13
SERVICE PROCEDURES
IGNITION TIMING PROCEDURE............ 15
POWERTRAIN CONTROL MODULE.......... 13
SPARK PLUG GAP ADJUSTMENT........... 13
GENERAL INFORMATION
INTRODUCTION
This group describes the ignition systems for the
2.4, 3.0, and 3.3/3.8L engines.
On Board Diagnostics is described in Group 25 -
Emission Control Systems.
Group 0 - Lubrication and Maintenance, contains
general maintenance information for ignition related
items. The Owner's Manual also contains mainte-
nance information.
POWERTRAIN CONTROL MODULE
The ignition system is regulated by the Powertrain
Control Module (PCM) (Fig. 1). The PCM supplies
battery voltage to the ignition coil through the Auto
Shutdown (ASD) Relay. The PCM also controls
ground circuit for the ignition coil. By switching the
ground path for the coil on and off, the PCM adjusts
ignition timing to meet changing engine operating
conditions.
During the crank-start period the PCM advances
ignition timing a set amount. During engine opera-
tion, the amount of spark advance provided by the
PCM is determined by the following input factors:
NSIGNITION SYSTEM 8D - 1

THROTTLE POSITION SENSOR (TPS)
The TPS mounts to the side of the throttle body
(Fig. 13).
The TPS connects to the throttle blade shaft. The
TPS is a variable resistor that provides the Power-
train Control Module (PCM) with an input signal
(voltage). The signal represents throttle blade posi-
tion. As the position of the throttle blade changes,
the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade
position. The TPS output voltage to the PCM varies
from approximately 0.40 volt at minimum throttle
opening (idle) to a maximum of 3.80 volts at wide
open throttle.
Along with inputs from other sensors, the PCM
uses the TPS input to determine current engine oper-
ating conditions. The PCM also adjusts fuel injector
pulse width and ignition timing based on these
inputs.
LOCK KEY CYLINDER
The lock cylinder is inserted in the end of the
housing opposite the ignition switch. The ignition key
rotates the cylinder to 5 different detents (Fig. 14):
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
KNOCK SENSOR
The knock sensor threads into the side of the cyl-
inder block in front of the starter motor. When the
knock sensor detects a knock in one of the cylinders,
it sends an input signal to the PCM. In response, the
PCM retards ignition timing for all cylinders by a
scheduled amount.
Knock sensors contain a piezoelectric material
which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal's vibration increase, the knock
sensor output voltage also increases.
Fig. 12 Engine Coolant Temperature SensorÐ3.3/
3.8LFig. 13 Throttle Position Sensor and Idle Air Control
Motor
Fig. 14 Ignition Lock Cylinder Detents
NSIGNITION SYSTEM 8D - 7
GENERAL INFORMATION (Continued)

(3) Remove ignition cables from the secondary tow-
ers of the coil. Measure the secondary resistance of
the coil between the towers of each individual coil
(Fig. 21). Secondary resistance should be 7,000 to
15,800 ohms. Replace the coil if resistance is not
within tolerance.
FAILURE TO START TEST
This no-start test checks the camshaft position sen-
sor and crankshaft position sensor.
The Powertrain Control Module (PCM) supplies 8
volts to the camshaft position sensor and crankshaft
position sensor through one circuit. If the 8 volt sup-
ply circuit shorts to ground, neither sensor will pro-
duce a signal (output voltage to the PCM).
When the ignition key is turned and left in the On
position, the PCM automatically energizes the Auto
Shutdown (ASD) relay. However, the controller de-en-
ergizes the relay within one second because it has
not received a camshaft position sensor signal indi-
cating engine rotation.
During cranking, the ASD relay will not energize
until the PCM receives a camshaft position sensor
signal. Secondly, the ASD relay remains energized
only if the controller senses a crankshaft position
sensor signal immediately after detecting the cam-
shaft position sensor signal.
(1) Check battery voltage. Voltage should be
approximately 12.66 volts or higher to perform fail-
ure to start test.
(2) Disconnect the harness connector from the coil
pack.
(3) Connect a test light to the B+ (battery voltage)
terminal of the coil electrical connector and ground
as shown in (Fig. 22). The B+ wire for the DIS coil is
dark green with an orange tracer.Do not spread
the terminal with the test light probe.(4) Turn the ignition key to theON position.The
test light should flash On and then Off.Do not turn
the Key to off position, leave it in the On posi-
tion.
(a) If the test light flashes momentarily, the
PCM grounded the Auto Shutdown (ASD) relay.
Proceed to step 5.
(b) If the test light did not flash, the ASD relay
did not energize. The cause is either the relay or
one of the relay circuits. Use the DRB scan tool to
test the ASD relay and circuits. Refer to the appro-
priate Powertrain Diagnostics Procedure Manual.
Refer to the wiring diagrams section for circuit
information.
(5) Crank the engine. (If the key was placed in the
off position after step 4, place the key in the On posi-
tion before cranking. Wait for the test light to flash
once, then crank the engine.)
(6) If the test light momentarily flashes during
cranking, the PCM is not receiving a crankshaft posi-
tion sensor signal. Use the DRB scan tool to test the
crankshaft position sensor and sensor circuits. Refer
to the appropriate Powertrain Diagnostics Procedure
Manual. Refer to the wiring diagrams section for cir-
cuit information.
(7) If the test light did not flash during cranking,
unplug the crankshaft position sensor connector.
Turn the ignition key to the off position. Turn the
key to the On position, wait for the test light to
momentarily flash once, then crank the engine. If the
test light momentarily flashes, the crankshaft posi-
tion sensor is shorted and must be replaced. If the
light did not flash, the cause of the no-start is in
Fig. 21 Checking Ignition Coil Secondary
ResistanceFig. 22 Ignition Coil Engine Harness Connector
8D - 10 IGNITION SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

IGNITION SWITCH AND LOCK CYLINDER
INDEX
page page
DESCRIPTION AND OPERATION
IGNITION INTERLOCK.................... 35
LOCK KEY CYLINDER.................... 35
REMOVAL AND INSTALLATION
IGNITION INTERLOCK.................... 38IGNITION SWITCH....................... 35
LOCK CYLINDER HOUSING............... 38
LOCK KEY CYLINDER.................... 38
DESCRIPTION AND OPERATION
IGNITION INTERLOCK
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Off, Run or Start position. In addi-
tion, the operator cannot rotate the key to the lock
position unless the shifter is in the park position. On
vehicles equipped with floor shift refer to Group 21 -
Transaxle for Automatic Transmission Shifter/Igni-
tion Interlock.
LOCK KEY CYLINDER
The lock cylinder is inserted in the end of the
housing opposite the ignition switch. The ignition key
rotates the cylinder to 5 different detents (Fig. 1):
²Accessory
²Off (lock)
²Unlock
²On/Run
²Start
REMOVAL AND INSTALLATION
IGNITION SWITCH
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig. 2).
For ignition switch terminal and circuit identifica-
tion, refer to Group 8W, Wiring Diagrams.
Fig. 1 Ignition Lock Cylinder Detents
Fig. 2 Ignition SwitchÐViewed From Below Column
NSIGNITION SYSTEM 8D - 35

REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining screws
(Fig. 3).
(3) Remove parking brake release cable from han-
dle (Fig. 4).
(4) Remove screws holding steering column
shrouds (Fig. 5) and remove lower shroud.
(5) Place key cylinder in RUN position. Depress
lock cylinder retaining tab and remove key cylinder
(Fig. 6).
(6) Remove ignition switch mounting screw (Fig. 7)
with a #10 Torxttamper proof bit.(7) Depress retaining tab (Fig. 3) or (Fig. 8) and
gently pry ignition switch from steering column (Fig.
9).
(8) Disconnect electrical connectors from ignition
switch and remove switch (Fig. 10).
Fig. 3 Steering Column Cover
Fig. 4 Parking Brake Release Cable
Fig. 5 Steering Column Shroud Screws
Fig. 6 Lock Cylinder Retaining Tab
8D - 36 IGNITION SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Ensure the ignition switch is in the RUN posi-
tion and the actuator shaft in the lock housing is in
the RUN position.(2) Install electrical connectors to ignition switch.
(3) Carefully install the ignition switch. The
switch will snap over the retaining tabs (Fig. 11).
Install mounting screw (Fig. 7).
(4) Install upper and lower shrouds.
(5) Install key cylinder (cylinder retaining tab will
depress only in the RUN position).
(6) Connect negative cable to battery.
(7) Check for proper operation of ignition switch
and key-in warning switch.
Fig. 7 Ignition Switch Mounting Screw
Fig. 8 Ignition Switch Retaining Tab
Fig. 9 Removing Ignition Switch
Fig. 10 Ignition Switch Connectors
Fig. 11 Ignition Switch Installation
NSIGNITION SYSTEM 8D - 37
REMOVAL AND INSTALLATION (Continued)

LOCK KEY CYLINDER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining screws
(Fig. 3).
(3) Remove screws holding steering column
shrouds (Fig. 5) and remove lower shroud.
(4) Place key cylinder in RUN position. Depress
lock cylinder retaining tab and remove key cylinder
(Fig. 6).
INSTALLATION
(1) Install key in lock cylinder. Turn key to run
position (retaining tab on lock cylinder can be
depressed).
(2) The shaft at the end of the lock cylinder aligns
with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the socket is
in the Run position (Fig. 12).
(3) Align the lock cylinder with the grooves in the
housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the hous-
ing.
(4) Turn the key to the Off position. Remove the
key.
(5) Install lower steering column shroud.
(6) Install steering column cover.(7) Connect negative cable to battery.
IGNITION INTERLOCK
Refer to Group 21, Transaxle for Shifter/Ignition
Interlock Service.
LOCK CYLINDER HOUSING
Refer to Steering Column in Group 19, Steering,
for Lock Cylinder Housing Service.
Fig. 12 Socket in Lock Cylinder Housing
8D - 38 IGNITION SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(4) Disengage park brake release cable case from
groove on end of release handle (Fig. 47).
(5) Disengage cable end pivot from slot on release
handle (Fig. 47).
INSTALLATION
For installation, reverse the above procedures,
MECHANICAL TRANSMISSION RANGE INDICATOR
REMOVAL
(1) Remove instrument cluster.
(2) Remove cluster lens.
(3) Remove screws holding mechanical transmis-
sion range indicator to back of cluster lens.
(4) Remove mechanical transmission range indica-
tor from cluster lens.
INSTALLATION
(1) Position transmission range indicator on clus-
ter lens.
(2) Install mechanical range indicator and attach-
ing screws to back of cluster lens.
(3) Install cluster lens.
(4) Install instrument cluster.
MESSAGE CENTER
REMOVAL
(1) Remove A-pillar trim.
(2) Remove instrument panel top cover. Refer to
instrument panel top cover removal procedures.
(3) Disconnect the wire connector from back of
message center.(4) Remove screws holding message center to
instrument panel top cover.
(5) Remove message center from instrument panel
top cover.
INSTALLATION
(1) Place message center in position on top cover.
(2) Install screws to hold message center to instru-
ment panel top cover.
(3) Connect wire connector into back of message
center.
(4) Install instrument panel top cover.
(5) Install A-pillar trim.
MESSAGE CENTER LAMP
REMOVAL
(1) Remove instrument panel top cover. Refer to
Instrument Panel Top Cover Removal procedures.
(2) Locate the lamp in question (Fig. 48).
(3) Remove lamp and check lamp. If lamp is good
test the power supply to the lamp.
INSTALLATION
For installation, reverse the above procedures.
OUTLET (12 VOLT) BASE
REMOVAL
(1) Look inside and note position of the retaining
bosses (Fig. 49).
(2) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(3) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 50).
(4) Disconnect the base wires.
(5) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position mount ring to the instrument panel
and feed the wires through ring. Index the cap and
the mount ring with the index tab at 9 o'clock to the
key in the instrument panel. Install the ring.
(2) Connect wires to base. Orient base alignment
rib at 11 o'clock to mate the groove in mount ring at
the same location
(3) Push base into the bezel till it locks.
(4) Install 12 volt outlet cap and check operation of
outlet or element.
OVER STEERING COLUMN BEZEL
REMOVAL
(1) Remove the lower steering column cover.
Fig. 47 Park Brake Release Handle
8E - 32 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)