1996 CHRYSLER VOYAGER engine coolant

(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)

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

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)

3.3/3.8L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
FIRING ORDERÐ3.3/3.8L................. 28
REMOVAL AND INSTALLATION
CAMSHAFT POSITION SENSOR............ 31
CRANKSHAFT POSITION SENSOR.......... 30
ENGINE COOLANT TEMPERATURE SENSOR . . 32
IGNITION COIL......................... 30
KNOCK SENSORÐ3.3/3.8L................ 32
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR............................. 32SPARK PLUG CABLE SERVICEÐ3.3/3.8L
ENGINES............................ 28
SPARK PLUG SERVICEÐ3.3/3.8L ENGINES . . . 29
THROTTLE POSITION SENSOR............ 32
SPECIFICATIONS
IGNITION COIL......................... 33
SPARK PLUG CABLE RESISTANCEÐ3.3/3.8L . . 34
SPARK PLUG........................... 33
TORQUE.............................. 34
DESCRIPTION AND OPERATION
FIRING ORDERÐ3.3/3.8L
The firing order for 3.3L and 3.8L engines is 1-2-3-
4-5-6.
REMOVAL AND INSTALLATION
SPARK PLUG CABLE SERVICEÐ3.3/3.8L ENGINES
WARNING: The ignition cables should not be
removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the
ignition cables.
The spark plug boot heat shield needs to be
installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly
engine misfire would occur.
Do not use pliers to pull the boot/heat shield
assembly from the spark plugs. This will damage the
shield assembly.
Spark plug boot heat shields must be replaced if
they are bent or damaged. It is extremely important
the shield is reinstalled correctly as shown. The bot-
tom of the spark plug heat shield must make contact
with the spark plug socket hex.
Firing OrderÐ3.3/3.8L
Fig. 1 Spark Plug Boot/Heat Shield Orientation
8D - 28 IGNITION SYSTEMNS

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
REMOVAL
(1) Disconnect electrical connector from MAP sen-
sor.
(2) Remove 2 screws holding sensor to intake man-
ifold (Fig. 9).
(3) Remove sensor from manifold.
INSTALLATION
Reverse the above procedure for installation.
ENGINE COOLANT TEMPERATURE SENSOR
The Engine Coolant Temperature (ECT) sensor is
located below the ignition coil (Fig. 10).
REMOVAL
(1) Drain cooling system until coolant level is
below sensor. Refer to Group 7, Cooling System.
(2) Remove electrical connector from coil (Fig. 11).
(3) Remove coil mounting screws.
(4) Rotate coil away from engine coolant tempera-
ture sensor.
(5) Disconnect electrical connector from engine
coolant temperature sensor.
(6) Remove sensor from engine.
INSTALLATION
(1) Tighten the sensor to 7 N´m (60 in. lbs.) torque.
(2) Connect electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
(4) Install coil. Tighten coil mounting screws to 12
N´m (105 in. lbs.) torque.
(5) Connect electrical connector to coil.
THROTTLE POSITION SENSOR
Refer to Group 14, Fuel Injection Section, for
Removal/Installation.
KNOCK SENSORÐ3.3/3.8L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 12).
Fig. 8 Camshaft Position Sensor and Spacer
Fig. 9 Manifold Absolute Pressure Sensor
Fig. 10 Engine Coolant Temperature Sensor
Fig. 11 Ignition Coil Removal
8D - 32 IGNITION SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

SPARK PLUG
* New Spark Plug Gap
TORQUE
DESCRIPTION......................TORQUE
3.3L Camshaft Position
Sensor Screw.............12N´m(105 in. lbs.)
3.3L Engine Coolant Sensor......7N´m(60in.lbs.)
3.3L Crankshaft Position
Sensor Screw.............12N´m(105 in. lbs.)
3.3/3.8L Ignition Coil.........12N´m(105 in. lbs.)
Ignition Switch...............2N´m(17in.lbs.)
Spark Plugs.................28N´m(20ft.lbs.)
SPARK PLUG CABLE RESISTANCEÐ3.3/3.8L
Engine Spark Plug Gap * Thread Size
3.3L RN14PMP5 0.048 TO 0.053 14mm (3/4 in.) reach
3.8L RN14PMP5 0.048 TO 0.053 14mm (3/4 in. ) reach
CABLE Maximum
Resistance
#1 18.5K ohms
#2 15.5K ohms
#3 20.4K ohms
#4 21.2K ohms
#5 27.7K ohms
#6 26.7K ohms
8D - 34 IGNITION SYSTEMNS
SPECIFICATIONS (Continued)

BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION....................... 17
CLEANING AND INSPECTION
HEADLAMP CLEANING.................. 17SPECIFICATIONS
EXTERIOR LAMP BULBS................. 17
INTERIOR LAMP BULBS................. 17
GENERAL INFORMATION
INTRODUCTION
The following Bulb Application Tables list the lamp
title on the left side of the column and trade number
or part number on the right.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
If a halogen bulb is contaminated with oil, clean
bulb with denatured alcohol or ammonia based sol-
vent.
CLEANING AND INSPECTION
HEADLAMP CLEANING
This vehicle is equipped with plastic headlights
that are lighter and less susceptible to stone break-
age than glass headlights.
This plastic is not as scratch resistant as glass and
therefore a different lens cleaning procedures must
be followed.
To minimize the possibility of scratching the lenses
and reducing light output, avoid wiping with a dry
cloth. To remove road dirt, wash with a mild soap
solution followed by rinsing with water.
Do not use abrasive cleaning components, solvents,
steel wool or other aggressive material to clean the
lenses.
SPECIFICATIONS
EXTERIOR LAMP BULBS
LAMP BULB
Back-up.............................P21W
CHMSL (Non-Solar Tint)................P21W
CHMSL (Solar Tint)....................R10WLAMP BULB
Fog Lamp..............................H3
Headlamp..............................H4
License Plate..........................C5W
Front Turn Signal....................PY21W
Citylight..............................T4W
Front Side Repeater.....................T4W
Tail, Stop...........................P21/5W
Rear Turn Signal......................P21W
Rear Fog Lamp........................P21W
INTERIOR LAMP BULBS
LAMP BULB
ABS ................................PC194
AirBag .............................PC194
Alarm Set (Security/Immobilzer)..........PC194
Brake Warning.......................PC194
Center/Rear Reading Lamps...............578
Center/Rear Dome Lamps.................579
Cruise Indicator.......................PC194
Door Ajar Indicator....................PC194
Engine Compartment Lamps...............579
Engine Temp Indicator.................PC194
Front Door Courtesy......................567
Glove Box Lamp.........................194
Glow Plug Indicator (Diesel Engine Only) . . . PC194
High Beam Indicator...................PC194
Instrument Cluster....................PC194
IP/Ash Tray (Left Hand Drive Only).........161
Liftgate Flood Lamps.....................567
Liftgate Ajar Indicator...................PC74
Low Coolant Level (Diesel Engine Only).....PC74
Low Fuel Indicator....................PC194
Low Volts Warning.....................PC74
Low Washer Fluid......................PC74
Oil Pressure Indicator..................PC194
O/H Console Reading Lamps...............579
Seat Belt Indicator (Except Diesel).........PC74
Service Engine Soon...................PC194
Turn Signal..........................PC194
Visor Vanity Lamp...................6501966
NS/GSLAMPS 8L - 17