2001 CHRYSLER VOYAGER engine

HORN
TABLE OF CONTENTS
page page
HORN
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................1
HORN
DIAGNOSIS AND TESTING..................3
REMOVAL...............................4INSTALLATION............................5
HORN RELAY
DIAGNOSIS AND TESTING..................5
REMOVAL...............................5
INSTALLATION............................5
HORN SWITCH
DESCRIPTION............................5
HORN
DESCRIPTION
HORN SYSTEM
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAG, REFER TO
ELECTRICAL, RESTRAINTS FOR SAFETY PRECAU-
TIONS. DISCONNECT THE NEGATIVE CABLE FROM
THE BATTERY BEFORE SERVICING COMPONENTS
INVOLVING THE AIRBAG SYSTEM. ACCIDENTAL
DEPLOYMENT OF AIRBAG AND PERSONAL INJURY
CAN RESULT.
The horn circuit consists of a horn switch, clock-
spring, horn relay, horns and intelligent power mod-
ule. The horn switch is a membrane switch located in
the airbag trim cover. The horns are located forward
of the left front wheel behind the bumper fascia.
OPERATION
The horn relay plugs into the intelligent power
module which is located in the engine compartment.
For circuit information and component locations,
refer to the appropriate wiring information. The wir-
ing information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
The horns will not function if the switch is
ªCLOSEDº for more than 30 seconds. Once the
switch is ªOPENº, a 20±30 second delay will occur
before the horns are functional again.
DIAGNOSIS AND TESTING
Refer to Horn System Test below. If the horn does
not sound, check horn fuse located in the intelligent
power module. If the fuse is blown, replace with the
correct fuse. If the horns fail to sound and the new
fuse blows when depressing the horn switch, a short
circuit in the horn or the horn wiring between the
fuse terminal and the horn is responsible, or a defec-
tive horn switch allowed the horn to burn out is
responsible.
If the fuse is OK, test horn relay (Refer to 8 -
ELECTRICAL/HORN/HORN RELAY - DIAGNOSIS
AND TESTING).
If the relay is OK, test horn. Refer to Horn System
Test.
CAUTION:
Continuous sounding of horn may cause horn relay
to fail.
Should the horn sound continuously:
²Unplug the horn relay from intelligent power
module.
²Refer to (Refer to 8 - ELECTRICAL/HORN/
HORN RELAY - DIAGNOSIS AND TESTING).
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
RSHORN8H-1

IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION............................1
OPERATION.............................1
SPECIFICATIONS.........................1
AUTO SHUT DOWN RELAY
DESCRIPTION............................3
OPERATION.............................3
CAMSHAFT POSITION SENSOR
DESCRIPTION............................3
OPERATION.............................3
REMOVAL...............................3
INSTALLATION............................5
IGNITION COIL
DESCRIPTION............................6
OPERATION.............................6REMOVAL...............................6
INSTALLATION............................6
KNOCK SENSOR
DESCRIPTION............................7
OPERATION.............................7
REMOVAL...............................7
INSTALLATION............................8
SPARK PLUG
DESCRIPTION............................8
REMOVAL...............................9
INSTALLATION............................9
SPARK PLUG CABLE
DESCRIPTION............................9
REMOVAL...............................9
INSTALLATION............................9
IGNITION CONTROL
DESCRIPTION - IGNITION SYSTEM
NOTE: All engines use a fixed ignition timing sys-
tem. Basic ignition timing is not adjustable. All
spark advance is determined by the Powertrain
Control Module (PCM).
The distributorless ignition system used on these
engines is referred to as the Direct Ignition System
(DIS). The system's three main components are the
coils, crankshaft position sensor, and camshaft posi-
tion sensor. The coil on plug ignition system utilizesan ignition coil for every cylinder, it is mounted
directly over the each spark plug.
OPERATION - IGNITION SYSTEM
The crankshaft position sensor and camshaft posi-
tion sensor are hall effect devices. The camshaft posi-
tion sensor and crankshaft position sensor generate
pulses that are inputs to the PCM. The PCM deter-
mines engine position from these sensors. The PCM
calculates injector sequence and ignition timing from
crankshaft & camshaft position. For a description of
both sensors, refer to Camshaft Position Sensor and
Crankshaft Position Sensor in this section.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
2.4L Target Magnet Screw 3 30
2.4L Camshaft Sensor Screw 12.9 115
3.3/3.8L Camshaft Sensor Screw 14.1 125
2.4L Ignition coil bolts 11.8 105
3.3/3.8L Ignition coil bolts 11.8 105
Spark Plugs 17.5 13
Knock Sensor 10 7
RSIGNITION CONTROL8I-1

SPARK PLUG CABLE RESISTANCE
2.4L
CABLE Maximum Resistance
1, 2, 3, & 4 10.8K ohms
3.3/3.8L
CABLE Maximum Resistance
#1 22.5K ohms
#2 22.8K ohms
#3 19.3K ohms
#4 19.3K ohms
#5 13.6K ohms
#6 16.4K ohms
SPARK PLUG
Engine Spark Plug Gap Thread Size
2.4L RE14MCC5 0.048 TO 0.053 14mm (1 in.) reach
Engine Spark Plug Gap Thread Size
3.3L RN14PMP5 0.048 TO 0.053 14mm (1 in.) reach
3.8L RN14PMP5 0.048 TO 0.053 14mm (1 in. ) reach
FIRING ORDER
FIRING ORDER 2.4L
Fig. 1 Firing Order 3.3/3.8L
8I - 2 IGNITION CONTROLRS
SPECIFICATIONS (Continued)

AUTO SHUT DOWN RELAY
DESCRIPTION
The relay is located in the Power Distribution Cen-
ter (PDC). For the location of the relay within the
PDC, refer to the PDC cover for location. Check elec-
trical terminals for corrosion and repair as necessary
OPERATION
The ASD sense circuit informs the PCM when the
ASD relay energizes. A 12 volt signal at this input
indicates to the PCM that the ASD has been acti-
vated. This input is used only to sense that the ASD
relay is energized.
When energized, the ASD relay supplies battery
voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM
does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble
Code (DTC).
When energized, the ASD relay provides power to
operate the injectors, ignition coil, generator field, O2
sensor heaters (both upstream and downstream), and
also provides a sense circuit to the PCM for diagnos-
tic purposes. The PCM energizes the ASD any time
there is a Crankshaft Position sensor signal that
exceeds a predetermined value. The ASD relay can
also be energized after the engine has been turned
off to perform an O2 sensor heater test, if vehicle is
equipped with OBD II diagnostics.
As mentioned earlier, the PCM energizes the ASD
relay during an O2 sensor heater test. This test is
performed only after the engine has been shut off.
The PCM still operates internally to perform several
checks, including monitoring the O2 sensor heaters.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
The camshaft position sensorfor the 3.3/3.8L is
mounted in the front of the timing case cover (Fig. 7)
and the camshaft position sensor for the 2.4L is
mounted on the end of the cylinder head (Fig. 4).
OPERATION
The camshaft position sensor provides cylinder
identification to the Powertrain Control Module
(PCM) (Fig. 2). The sensor generates pulses as
groups of notches on the camshaft sprocket pass
underneath it (Fig. 3). The PCM keeps track of
crankshaft rotation and identifies each cylinder by
the pulses generated by the notches on the camshaftsprocket. Four crankshaft pulses follow each group of
camshaft pulses.
When the PCM receives 2 cam pulses followed by
the long flat spot on the camshaft sprocket, it knows
that the crankshaft timing marks for cylinder 1 are
next (on driveplate). When the PCM receives one
camshaft pulse after the long flat spot on the
sprocket, cylinder number 2 crankshaft timing marks
are next. After 3 camshaft pulses, the PCM knows
cylinder 4 crankshaft timing marks follow. One cam-
shaft pulse after the 3 pulses indicates cylinder 5.
The 2 camshaft pulses after cylinder 5 signals cylin-
der 6 (Fig. 3). The PCM can synchronize on cylinders
1or4.
When metal aligns with the sensor, voltage goes
low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a
group of notches pass under the sensor, the voltage
switches from low (metal) to high (notch) then back
to low. The number of notches determine the amount
of pulses. If available, an oscilloscope can display the
square wave patterns of each timing event.
Top Dead Center (TDC) does not occur when
notches on the camshaft sprocket pass below the cyl-
inder. TDC occurs after the camshaft pulse (or
pulses) and after the 4 crankshaft pulses associated
with the particular cylinder. The arrows and cylinder
call outs on Figure 4 represent which cylinder the
flat spot and notches identify, they do not indicate
TDC position.
REMOVAL - 2.4L
The camshaft position sensor is mounted to the
rear of the cylinder head.
(1) Remove the negative battery cable.
Fig. 2 Camshaft Position Sensor
1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
RSIGNITION CONTROL8I-3

(4) Remove bolt holding sensor.
(5) Rotate sensor away from block.
(6) Pull sensor up out of the chain case cover.Do
not pull on the sensor lead.There is an O-ring on
the sensor case. The O-ring may make removal diffi-
cult. A light tap to top of sensor prior to removal may
reduce force needed for removal.
INSTALLATION - 2.4L
The target magnet has locating dowels that fit into
machined locating holes in the end of the camshaft
(Fig. 8).(1) Install target magnet in end of camshaft.
Tighten mounting screw to 3 N´m (30 in. lbs.) torque.
Over torqueing could cause cracks in magnet. If mag-
net cracks replace it.
(2) Install camshaft position sensor. Tighten sensor
mounting screws to 12.9 N´m (115 in. lbs.) torque.
(3) Carefully attach electrical connector to cam-
shaft position sensor. Installation at an angle may
damage the sensor pins.
(4) Connect the negative battery cable.
INSTALLATION - 3.3/3.8L
If the removed sensor is reinstalled, clean off
the old spacer on the sensor face. A NEW
SPACER must be attached to the face before
installation.Inspect O-ring for damage, replace if
necessary. If the sensor is being replaced, confirm
that the paper spacer is attached to the face and
O-ring is positioned in groove of the new sensor (Fig.
9).
(1) Apply a couple drops of clean engine oil to the
O-ring prior to installation.
(2) Install sensor in the chain case cover and
rotate into position.
(3) Push sensor down until contact is made with
the camshaft gear. While holding the sensor in this
position, install and tighten the retaining bolt 14
N´m (125 in. lbs.) torque.
(4) Connect camshaft position sensor electrical
connector to harness connector.
(5) Install the air box cover and inlet hose (Fig. 6).
(6) Connect the negative battery cable.
Fig. 7 CAMSHAFT POSITION SENSOR
Fig. 8 Target Magnet Installation
1 - LOCATING DOWELS
2 - LOCATING HOLES (2)
Fig. 9 Camshaft Position Sensor and Spacer
1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
RSIGNITION CONTROL8I-5
CAMSHAFT POSITION SENSOR (Continued)

INSTALLATION - 3.3/3.8L
(1) Install coil over studs on bracket.
(2) Install 2 bolts to ignition coil.
(3) Install 2 nuts to the ignition coil studs. Tighten
nuts and bolts.
(4) Connect the electrical connector to the ignition
coil.
(5) Install the ignition cables to the ignition coil.
(6) Reposition the Power steering reservoir. Slide
bracket over the mounting stud (Fig. 12).
(7) Install 2 bolts the Power steering reservoir to
intake manifold.
(8) Tighten the lower nut to stud on ignition coil
bracket.
(9) Install the throttle and speed control cables to
clip.
(10) Connect the negative battery cable.
KNOCK SENSOR
DESCRIPTION
The knock sensor threads into the cylinder block.
The knock sensor is designed to detect engine vibra-
tion that is caused by detonation.
OPERATION
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 cyl-
inders 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 increases, the
knock sensor output voltage also increases.
The voltage signal produced by the knock sensor
increases with the amplitude of vibration. The PCM
receives as an input the knock sensor voltage signal.
If the signal rises above a predetermined level, the
PCM will store that value in memory and retard
ignition timing to reduce engine knock. If the knock
sensor voltage exceeds a preset value, the PCM
retards ignition timing for all cylinders. It is not a
selective cylinder retard.
The PCM ignores knock sensor input during engine
idle conditions. Once the engine speed exceeds a
specified value, knock retard is allowed.
Knock retard uses its own short term and long
term memory program.
Long term memory stores previous detonation
information in its battery-backed RAM. The maxi-
mum authority that long term memory has over tim-
ing retard can be calibrated.
Short term memory is allowed to retard timing up
to a preset amount under all operating conditions (as
long as rpm is above the minimum rpm) except WOT.
The PCM, using short term memory, can respond
quickly to retard timing when engine knock is
detected. Short term memory is lost any time the
ignition key is turned off.
NOTE: Over or under tightening affects knock sen-
sor performance, possibly causing improper spark
control.
REMOVAL - 2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 13).
(1) Disconnect electrical connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensors.
REMOVAL - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) On All Wheel Drive vehicles remove the PTU
(Power Transfer Unit), refer to the Transmission sec-
tion for more information.
(4) Disconnect electrical connector from knock sen-
sor.
(5) Use a crow foot socket to remove the knock
sensor.
Fig. 12 IGNITION COIL BRACKET 3.3/3.8L
RSIGNITION CONTROL8I-7
IGNITION COIL (Continued)

INSTALLATION - 2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 13).
(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.
INSTALLATION - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(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.
(3) On All Wheel Drive vehicles install the PTU
(Power Transfer Unit) for the rear wheels, refer to
the Transmission section for more information.
(4) Lower vehicle.
(5) Connect the negative cable.
SPARK PLUG
DESCRIPTION - STANDARD 2.4L
All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Refer to the Specifications section for gap and type
of spark plug.
DESCRIPTION - PLATINUM 3.3/3.8L
These engines utilize platinum spark plugs. Refer
to the maintenance schedule.
All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
The spark plugs are double platinum and have a
recommended service life of 100,000 miles for normal
driving conditions per schedule A in this manual. The
spark plugs have a recommended service life of
75,000 miles for severe driving conditions per sched-
ule B in this manual. A thin platinum pad is welded
to both electrode ends as show in (Fig. 14). Extreme
care must be used to prevent spark plug cross
threading, mis-gaping and ceramic insulator damage
during plug removal and installation.
Fig. 13 Knock Sensor
1 - GENERATOR
2 - INTAKE MANIFOLD
3 - KNOCK SENSOR
4-STARTER
Fig. 14 Platinum Pads
1 - APPLY ANTI-SEIZE COMPOUND HERE ONLY
2 - PLATINUM SPARK SURFACE
8I - 8 IGNITION CONTROLRS
KNOCK SENSOR (Continued)

INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................1
INSTRUMENT CLUSTER..................1
REMOVAL..............................11
INSTALLATION...........................11
CLUSTER LENS
REMOVAL..............................12INSTALLATION...........................12
MECHANICAL TRANSMISSION RANGE
INDICATOR
REMOVAL..............................12
INSTALLATION...........................12
RED BRAKE WARNING INDICATOR
DESCRIPTION...........................12
OPERATION.............................12
INSTRUMENT CLUSTER
DESCRIPTION
The instrumentation gauges are contained in a
subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the
cluster gauges becomes faulty, the entire cluster
would require replacement.
The mechanical instrument cluster with a tachom-
eter is equipped with a electronic vacuum fluorescent
transmission range indicator (PRND3L), odometer,
and trip odometer display.
The mechanical instrument cluster without a
tachometer is equipped with a cable operated trans-
mission range indicator (PRND21) and a vacuum
flourescent odometer display.
The instrument cluster is equipped with the follow-
ing warning lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
²Headlamp Out
²Coolant Temperature
²Anti-Lock Brake
²Brake
²Airbag
²Traction Control
²Autostick
OPERATION
Refer to the vehicle Owner's Manual for operation
instructions and conditions for the Instrument Clus-
ter Gauges.
DIAGNOSIS AND TESTING - SELF-
DIAGNOSTICS
The instrument clusters are equipped with a self
diagnostic test feature to help identify electronic
problems. Prior to any test, perform the Self-Diag-
nostic Test. The self diagnostic system displays
instrument cluster stored fault codes in the odometer
display, sweeps the gauges to the calibration points,
and bulb checks the warning indicators. When the
key is in the ON position with the engine not run-
ning, the MIL will remain illuminated for regulatory
purposes.
To activate the Self-Diagnostic program:
(1) With the ignition switch in the OFF position,
depress the TRIP ODOMETER RESET button.
(2) Continue to hold the TRIP ODOMETER
RESET button untilSofand a number (software ver-
sion number (i.e.Sof 3.2) appears in the odometer
window (about five seconds) then release the button.
If a fault code is present, the cluster will display it in
the odometer display. When all fault codes have been
displayed, the cluster will displayªendºin the odom-
eter display. Refer to the table to determine what
each trouble code means.
RSINSTRUMENT CLUSTER8J-1