1996 CHRYSLER VOYAGER coolant

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)

TEMPERATURE GAUGE DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT1. Internal Cluster Failure. 1. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
²If temperature gauge pointer moves to calibration
points during test and fault codes 110 or 111 don't
appear in the odometer display then failure is not in the
cluster. Look for another possible cause of failure.
²If the pointer doesn't move during test, go to Step
(b).
²If fault code 110 is displayed in the odometer, go to
Step (b).
²If fault code 111 is displayed in the odometer then go
to Step (f).
²If fault codes 920 or 940 are displayed refer to the
fault code chart to identify which module is causing the
fault and repair module.
(b) Replace main cluster pc board. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
(e) Replace subdial assembly and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the temperature gauge failure.
(f) Use a scan tool to calibrate temperature gauge and
perform Self Diagnostic Test. If OK, stop. If not OK, go
to Step (b).
2. No CCD Temperature
Message or Cold CCD
Bus Message from the
Body Control Module.2. (a) Check BCM fault codes using a scan tool. If
there are not faults, go to Step (b). If there are faults,
refer to the BCM section of the manual to properly
diagnose and repair.
(b) Check PCM fault codes using a scan tool. If there
are no faults, go to Step (c). If there are faults, refer to
the PCM section of the manual to properly diagnose
and repair.
(c) Refer to the coolant sensor section of the service
manual for the coolant sensor test procedure. Repair
sensor as needed.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 11
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT.1. Bad CCD Bus
Message from the Body
Control Module.1. (a) Check BCM fault codes using a scan tool. If
there are no faults, go to Step (b). If there are faults,
refer to the BCM section of the manual to properly
diagnose and repair.
(b) Check PCM fault codes using a scan tool. If there
are no faults, go to Step (c). If there are faults, refer to
the PCM section of the manual to properly diagnose
and repair.
(c) Refer to the coolant sensor section of the service
manual for the coolant sensor test procedure. Repair
sensor as needed.
2. Internal Cluster Failure. 2. (a) Perform Cluster Self Diagnostic Test and check
for fault codes.
²If the pointer moves during test but still appears
erratic and fault codes 110 or 111 don't appear in the
odometer display, go to Step (b).
²If fault code 110 is displayed in the odometer, go to
Step (e).
²If fault code 111 appears in the odometer display go
to Step (d).
²If fault code 920 or 940 is displayed refer to the fault
code chart to identify which mode is causing the fault
and repair module.
(b) Replace cluster subdial assembly. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. DO NOT COMPLETELY INSTALL
CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS
CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go Step (e).
(e) Replace main cluster pc board and use a scan tool
to calibrate cluster. If not OK, look at another possible
cause for the temperature gauge failure.
TEMPERATURE GAUGE
INACCURATE.1. Temperature Gauge
Out of Calibration.1. (a) Perform Cluster Self-Diagnostic Test.
²If pointer is accurate to the calibration points look for
another possible cause of failure.
²If pointer is inaccurate to the calibration points, go
the Step (b).
(b) Use a scan tool to calibrate temperature gauge.
2. Coolant Sensor Out of
Calibration.2. Refer to the Cooling section of the service manual
for test and repair procedure.
8E - 12 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

INSTRUMENT CLUSTER
The mechanical instrument cluster with a tachom-
eter is equipped with a electronic vacuum fluorescent
odometer, and trip odometer display.
The instrument cluster is equipped with the follow-
ing warning lamps (Fig. 2).
²Battery Voltage
²Lift Gate Ajar²Low Coolant
²Low Windshield Washer Fluid Level
²Door Ajar
²Glow Plug Indicator
²Low Fuel Level
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
GS vehicle instrument clusters are equipped with a
self diagnostic test feature to help identify electronic
problems. Prior to any test, perform Self Diagnostic
Test. The self diagnostic system monitors the CCD
bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in
the odometer window of the cluster.
The following CCD bus messages are continuously
monitored by the diagnostic system:
²Body Control Module
²Powertrain Control Module
HEADLAMP SWITCH
Using a Digital Multimeter, equipped with a diode
test to perform the Headlamp Switch Test below (Fig.
3).
Switch position possibilities are open (no continu-
ity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine
meter setting. If Headlamp Switch is not within spec-
ifications replace as necessary.
Fig. 2 Instrument Cluster
Fig. 1 Headlamp and Mirror Switch Lamps
8E - 2 INSTRUMENT PANEL AND SYSTEMSNS/GS
DESCRIPTION AND OPERATION (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

(2) Inspect BCM connectors and wires for proper
connection. If OK, replace BCM for tone condition.
DOME LAMP ON CHIME
The dome lamp on chime will warn the driver that
the dome lamps have been left on.
With the ignition is OFF:
²Driver's door OPEN (door ajar switch is closed to
ground)
²Dome lamps are ON (dome lamp switch is closed
to ground),
The chime will sound continuously until driver's
door is closed, dome lamps tuned OFF or until the
battery protection time out of 15 minutes has
expired. Refer Group 8L, Lamps proper procedures.
Chime rate: 168 to 192 chimes per minute.
ENGINE TEMPERATURE CRITICAL CHIME
The engine temperature critical chime will warn
the driver that the vehicle's engine is overheating.
While monitoring the coolant temperature, the Pow-
ertrain Control Module (PCM) will send on the CCD
bus as engine temperature every 1.376 seconds to the
Body Control Module (BCM). The BCM calculates
engine temperature and determines if a warning
should occur. This feature is functional only with the
Ignition Switch in the Run/Start position.
When the engine temperature reaches 122ÉC
(252ÉF) the BCM will chime one tone and the engine
temperature lamp comes ON. The BCM turns OFF
the lamp when the engine temperature reaches
117ÉC (242ÉF). The BCM will chime continuously
when the engine temperature reaches 125ÉC (257ÉF).
The chime will turn OFF after four minutes or when
the temperature reaches 117ÉC (242ÉF), which ever
occurs first.
EXTERIOR LAMPS ON CHIME
The exterior lamp on chime will warn the driver
that the exterior lights have been left on.
With the ignition switch OFF:
²Driver's door is open (door ajar switch is closed
to ground)
²Parking lamps or headlamps ON (parking lamp
switch is closed to ground)
The chime will sound until lights are turned OFF,
driver's door closed or until the battery protection
time out of 3 minutes has expired.
Refer to Group 8L, Lamps, for proper service pro-
cedures. Chime rate: 168 to 192 chimes per minute.
To test the exterior lamps left on function:
²Turn ignition off
²Remove ignition key
²Turn exterior lamps on with driver's door open.
Chime should sound until lamps are turned off or
driver's door is closed.
KEY-IN IGNITION CHIME
The key-in ignition chime will act as a warning to
the driver that the ignition key has been left in the
ignition switch.
With the ignition switch is in OFF position ONLY:
²Driver's door is open/ajar (door ajar switch is
closed to ground)
²Key is in the ignition switch (key-in ignition
switch is closed to ground)
The chime will sound until one of the above condi-
tions is removed. Chime rate: 168 to 192 chimes per
minute.
To test the key-in ignition function, insert key into
the ignition and open driver's door. Do not turn igni-
tion ON. Chime should sound until key is removed
from ignition or driver's door is closed.
LOW OIL PRESSURE CHIME OPERATION
The low oil pressure chime will warn the driver
that the engine oil pressure is low. The oil pressure
switch, will close to ground during a low oil pressure
condition. The oil pressure lamp will illuminate in
the message center. The body control module will
monitor the oil pressure switch and signal a low oil
pressure condition. A continuous four minute warn-
ing chime will sound and the oil pressure lamp will
come ON when the following conditions are met:
²Ignition on and engine not cranking
²Engine running at 420 to 480 rpm for 10 sec-
onds
²Oil pressure switch closed to ground for (1 sec-
ond minimum, 2 seconds maximum)
Chime rate: 168 to 192 chimes per minute.
SEAT BELT CHIME
The seat belt chime will sound for 4 to 8 seconds,
when the ignition is turned on and the driver's seat
belt is not buckled (seat belt switch is closed to
ground). This is a reminder to the driver to buckle
the seat belt. The seat belt lamp is controlled by the
mechanical instrument cluster. The cluster will also
illuminate the seat belt warning lamp for 6 seconds.
Buckling the driver's seat belt before the time out
has expired will cause the chime to stop immediately.
Chime rate: 38 to 62 chimes per minute.
To test the seat belt warning system, the ignition
switch must be in the OFF position for 1 minute
before starting the test. Turn the ignition switch to
the on position with the driver's seat belt not buck-
led. The seat belt warning lamp should light and the
chime should sound 4 to 8 seconds.
SEAT BELT LAMP
The seat belt lamp in the instrument cluster sig-
nals the vehicle passengers to fasten their seat belts.
The seat belt lamp is illuminated directly by the
8U - 2 CHIME WARNING/REMINDER SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

instrument cluster for 6 seconds after the instrument
cluster receives the message from the Body Control
Module. The seat belt lamp is therefore illuminated
for 6 seconds whenever the ignition switch is moved
to run/start position.
(1) While ignition is off, the seat belt lamp will not
be illuminated.
(2) The ignition power feed status will be updated
every 250 milliseconds or on change.
(3) This lamp will be checked by the instrument
cluster for 6 seconds with every run/start cycle of the
ignition switch.
TURN SIGNAL ON CHIME
The turn signal on chime will warn the driver that
the turn signals have been left on. When the body
control module receives a turn signal input for 6.4
km (4.0 miles), vehicle speed is greater than 24 km/h
(15 mph), the chime will sound continuously until the
turn signal is turned OFF. If vehicle speed drops
below 24 km/h (15 mph) prior to the warning being
activated, the accumulated distance traveled will be
reset. The turn signal chime is not activated when
the emergency flashers are turned on. This feature
can also be disabled in EEPROM. Chime rate: 50
chimes per minute.
For the turn signal warning system to operate:
²Must have input from either the right or left
turn signal lamps. Creates a voltage change between
0 and battery voltage.
²The vehicle speed sensor sends a message to the
Powertrain Control Module that vehicle has exceeded
24 km/h (15 mph) for 6.4 km (4.0 miles).
²When the above two conditions are met, the
chime will sound. The chime will stop when no fur-
ther voltage change is detected.²If hazard warning signals are pulsing, no chime
will sound.
²If speed drops below 24 km/h (15 mph) before
the warning is issued, the warning will not be issued
and the distance counter will be reset.
²If turn signal lamps are not working properly,
the chime will not sound.
²When using the scan tool, refer to the proper
Body Diagnostic Manual for the procedure.
WARNING LAMP ANNOUNCEMENT CHIME
The warning lamp announcement chime will warn
the driver to scan the instrument cluster to observe
which warning lamp is illuminated. Whenever the
volts, low fuel, low washer/coolant level, door ajar or
gate ajar lamps are first illuminated, the chime will
sound one tone. The door/liftgate ajar warning lamp
announcement chime sounds only if the vehicle speed
is above 2 m.p.h.
Two seconds after ignition switch is turned ON or
until the seat belt warning chime ends, all warning
announcement chimes will be consolidated into one
warning announcement. This will occur 2 seconds
after the seat belt warning chime ends. If a warning
announcement should occur while another warning
chime in progress (turn signal, low oil pressure or
high speed warnings), no additional chimes will
sound after the chime in progress ends. All associ-
ated lamps will be illuminated, and the active chime
will be the warning announcement.
NSCHIME WARNING/REMINDER SYSTEM 8U - 3
DIAGNOSIS AND TESTING (Continued)