1996 CHRYSLER VOYAGER odometer

JUNCTION
BLOCK ST-RUN-OFF A81
10A
FUSE
2
10C4
11F11
20
RD/WT
D1
18
VT/BR
ES13
D2
18
WT/BK
TRANSMISSION
CONTROL
MODULE
CONTROLPRNDL ELECTRONIC
ODOMETER
CONTROL
INDICATOR PRNDL
ELECTRONIC
ODOMETERODOMETER
TRIP
WT/BK18 D2VT/BR18D1
WT/BR20 D2VT/BR20 D1
2B33
E36 BS06
B23 P18
13
VT/BR18D1
7
BS05
12
BUS CCD
59C2
(+)BUS CCD
60C2
(-) D2
18
WT/BKMODULE CONTROL
POWERTRAIN BODY
CONTROL
MODULE
CONTROL ODOMETERTRIP
VT/BR20 D1WT/BK20 D2 WT/BK20 D2
(-)
C234
CCD
BUS
PS02
D1
20
VT/BR
(+)
C23
CCD
BUS
PS01
910
CCD
BUS
(+) (-)BUS CCD
(ST-RUN-OFF)IGNITION
CLUSTER
INSTRUMENTFUSED
(EATX)
ES14 (EATX)
B13 B12
PAIR TWISTED TWISTED
PAIR43 4
(+) BUS CCD
BUS CCD
(-)
TWISTED
PAIR
D1
(8W-12-2) (8W-10-16)
(8W-12-9)
(8W-31-8)
(8W-30-4)
(8W-30-31) (8W-30-4)
(8W-30-31)
(8W-30-4) (8W-45-3)(8W-30-4)
(8W-30-31) (8W-30-4)
(8W-30-31)
NS/GS8W-40 INSTRUMENT CLUSTER 8W - 40 - 5
GS004005J988W-3

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)

IDLE SPECIFICATIONSÐ3.0L ENGINE
Odometer Reading Idle RPM
Below 1000 Miles.................560-910 RPM
Above 1000 Miles.................610-910 RPM
IDLE SPECIFICATIONSÐ3.3/3.3L ENGINE
Odometer Reading Idle RPM
Below 1000 Miles.................525±875 RPM
Above 1000 Miles.................575±875 RPM
(14) If idle rpm is not within specifications, shut
off the engine and clean the throttle body as follows:
(a) Remove the throttle body from engine.
WARNING: CLEAN THROTTLE BODY IN A WELL
VENTILATED AREA. WEAR RUBBER OR BUTYL
GLOVES, DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
(b) While holding the throttle open, spray the
entire throttle body bore and the manifold side of
the throttle plate with Mopar Parts Cleaner.Only
use Mopar Parts Cleaner to clean the throttle
body.
(c) Using a soft scuff pad, clean the top and bot-
tom of throttle body bore and the edges and mani-
fold side of the throttle blade.The edges of the
throttle blade and portions of the throttle
bore that are closest to the throttle blade
when closed, must be free of deposits.
(d) Use compressed air to dry the throttle body.
(e) Inspect throttle body for foreign material.
(f) Install throttle body on manifold.
(g) Repeat steps 1 through 12. If the minimum
air flow is still not within specifications, the prob-
lem is not caused by the throttle body.
(15) Shut off engine.
(16) Remove Air Metering Fitting 6457 from the
intake manifold PCV nipple. Reinstall the PCV valve
hose.
(17) Uncap the throttle body idle purge nipple and
connect the idle purge line.
(18) Remove DRB scan tool.
Fig. 101 PCV ValveÐ2.4L Engine
Fig. 102 PCV ValveÐ3.0L Engine
Fig. 103 PCV ValveÐ3.3/3.8L Engines
NSFUEL SYSTEM 14 - 63
DIAGNOSIS AND TESTING (Continued)

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
(1) Turn ignition key to Off.
(2) D
isconnect the PCV valve hose from the intake
manifold nipple (Fig. 31). Cap the PCV vacuum nipple.
(3) Disconnect purge hose from the nipple on the
throttle body (Fig. 32).(4) Use a piece of hose to attach Air Metering Ori-
fice 6457 (0.125 in. orifice) to the purge nipple on the
throttle body (Fig. 33).
(5) Ensure that all accessories are off.
(6) Connect the DRB scan tool to the data link
connector inside the passenger compartment.
(7) Run engine in Park or Neutral until the cooling
fan has cycled on and off at least once (180ÉF).
(8) Using the DRB scan tool, access Minimum Air-
flow Idle Speed.
(9) The following will then occur:
²Idle air control motor will fully close
²Idle spark advance will become fixed
²PCM will go open loop enriched
²DRB scan tool displays engine RPM
(10) If idle RPM is within the range shown in the
Idle Specification chart, throttle body minimum air-
flow is set correctly.IDLE SPECIFICATION Ð2.0L ENGINE
Odometer Reading Idle RPM
Below 1000 Miles...............550±1300 RPM
Above 1000 Miles...............600±1300 RPM
(11) If idle RPM is above specifications, use the
DRB scan tool to check idle air control motor opera-
tion. If idle air control motor is OK, replace throttle
body. If idle air flow is below specification, shut off
the engine and clean the throttle body as follows:
WARNING: CLEAN THROTTLE BODY IN A WELL
VENTILATED AREA. WEAR RUBBER OR BUTYL
GLOVES, DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
Fig. 31 PCV Vacuum Nipple
Fig. 32 Purge Hose
Fig. 33 Orifice 6457 Attached to Purge Nipple
NS/GSFUEL SYSTEMÐ2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 41
DIAGNOSIS AND TESTING (Continued)