2002 CHRYSLER CARAVAN battery

²Manifold pressure
²Injector pulse-width
²Spark-advance programs
²Shift-point strategies (F4AC1 transmissions
only, via the PCI bus)
²Idle speed
²Decel fuel shutoff
The PCM recognizes a decrease in manifold pres-
sure by monitoring a decrease in voltage from the
reading stored in the barometric pressure memory
cell. The MAP sensor is a linear sensor; as pressure
changes, voltage changes proportionately. The range
of voltage output from the sensor is usually between
4.6 volts at sea level to as low as 0.3 volts at 26 in. of
Hg. Barometric pressure is the pressure exerted by
the atmosphere upon an object. At sea level on a
standard day, no storm, barometric pressure is 29.92
in Hg. For every 100 feet of altitude barometric pres-
sure drops .10 in. Hg. If a storm goes through it can
either add, high pressure, or decrease, low pressure,
from what should be present for that altitude. You
should make a habit of knowing what the average
pressure and corresponding barometric pressure is
for your area.
REMOVAL
REMOVAL - 2.4L
(1) Disconnect the negative battery cable.
(2) Disconnect electrical connector and vacuum
hose from MAP sensor (Fig. 18).
(3) Remove two screws holding sensor to the
intake manifold.
REMOVAL - 3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Remove vacuum hose and mounting screws
from manifold absolute pressure (MAP) sensor (Fig.
19).
(3) Disconnect electrical connector from sensor.
Remove sensor.
INSTALLATION
INSTALLATION - 2.4L
(1) Install sensor.
(2) Install two screws and tighten.
(3) Connect the electrical connector and vacuum
hose to the MAP sensor (Fig. 18).
(4) Connect the negative battery cable.
INSTALLATION - 3.3/3.8L
(1) Install sensor (Fig. 19).(2) Install screws and tighten toPLASTIC MAN-
IFOLD 1.7 N´m (15 in. lbs.) ALUMINUM MANI-
FOLD 3.3 N´m (30 in. lbs.).
(3) Connect the electrical connector to the sensor.
Install vacuum hose.
(4) Connect the negative battery cable.
O2 SENSOR
DESCRIPTION
The upstream oxygen sensor threads into the out-
let flange of the exhaust manifold (Fig. 20) or (Fig.
21).
Fig. 20 O2 SENSOR UPSTREAM 1/1 - 2.4L
Fig. 21 O2 SENSOR UPSTREAM 1/1 - 3.3/3.8L
14 - 30 FUEL INJECTIONRS
MAP SENSOR (Continued)
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stream sensor begins to match the upstream sensor
input except for a slight time delay. By comparing
the downstream heated oxygen sensor input to the
input from the upstream sensor, the PCM calculates
catalytic convertor efficiency. Also used to establish
the upstream O2 goal voltage (switching point).
REMOVAL
REMOVAL - UPSTREAM 1/1 - 2.4L
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Disconnect the electrical connector (Fig. 21).
(4) Use a socket such as the Snap-OntYA8875 or
equivalent to remove the sensor
(5) When the sensor is removed, the threads must
be cleaned with an 18 mm X 1.5 + 6E tap. If using
the original sensor, coat the threads with Loctite
771±64 anti-seize compound or equivalent.
REMOVAL - UPSTREAM 1/1 - 3.3/3.8L
(1) Remove battery, refer to the Battery section for
more information.
(2) Remove the battery tray, refer to the Battery
section for more information.
(3) Disconnect the speed control vacuum harness
from servo.
(4) Disconnect the electrical connector from servo.
(5) Remove the speed control servo and bracket
and reposition.
(6) Use a socket such as the Snap-OntYA8875 or
equivalent to remove the sensor (Fig. 23).(7) When the sensor is removed, the threads must
be cleaned with an 18 mm X 1.5 + 6E tap. If using
the original sensor, coat the threads with Loctite
771±64 anti-seize compound or equivalent.
REMOVAL - DOWNSTREAM 1/2 - 2.4/3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Disconnect the electrical connector (Fig. 24).
(4) Use a socket such as the Snap-OntYA8875 or
equivalent to remove the sensor (Fig. 25).
(5) When the sensor is removed, the threads must
be cleaned with an 18 mm X 1.5 + 6E tap. If using
the original sensor, coat the threads with Loctite
771±64 anti-seize compound or equivalent.
INSTALLATION
INSTALLATION - UPSTREAM 1/1 - 2.4L
The engines uses two heated oxygen sensors.
(1) After removing the sensor, the exhaust mani-
fold threads must be cleaned with an 18 mm X 1.5 +
6E tap. If reusing the original sensor, coat the sensor
threads with an anti-seize compound such as Loctite
771- 64 or equivalent. New sensors have compound
on the threads and do not require an additional coat-
ing.
(2) Install sensor and tighten to 27 N´m (20 ft.
lbs.) (Fig. 21).
(3) Connect the electrical connector for the O2 sen-
sor and install onto bracket.
(4) Lower vehicle.
(5) Connect the negative battery cable.
Fig. 23 O2 SENSOR 1/1
Fig. 24 Downstream Oxygen Sensor (1/2)
1 - OXYGEN SENSOR CONNECTOR
2 - CATALYTIC CONVERTER
3 - DOWNSTREAM OXYGEN SENSOR
4 - ENGINE HARNESS CONNECTOR
14 - 32 FUEL INJECTIONRS
O2 SENSOR (Continued)
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INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L
The engines uses two heated oxygen sensors.
(1) After removing the sensor, the exhaust mani-
fold threads must be cleaned with an 18 mm X 1.5 +
6E tap. If reusing the original sensor, coat the sensor
threads with an anti-seize compound such as Loctite
771- 64 or equivalent. New sensors have compound
on the threads and do not require an additional coat-
ing.
(2) Install sensor and tighten to 27 N´m (20 ft.
lbs.).
(3) Connect the electrical connector for the O2 sen-
sor and install onto bracket.
(4) Connect the electrical connector for the speed
control servo.
(5) Install the speed control servo and bracket
refer to the Speed Control Servo for more informa-
tion.
(6) Connect the speed control vacuum harness to
servo.
(7) Install the battery tray, refer to the Battery
section for more information.
(8) Install battery, refer to the Battery section for
more information.
INSTALLATION DOWNSTREAM 2/1 -
2.4/3.3/3.8L
The O2S is located on the side of the catalytic con-
verter.
Threads of new oxygen sensors are factory coated
with anti-seize compound to aid in removal.DONOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) Install sensor and tighten to 27 N´m (20 ft.
lbs.).
(2) Connect the electrical connector.
(3) Lower vehicle.
(4) Install the negative battery cable.
THROTTLE BODY
DESCRIPTION
The throttle body is located on the intake manifold
(Fig. 26) or (Fig. 27). Fuel does not enter the intake
manifold through the throttle body. Fuel is sprayed
into the manifold by the fuel injectors.
OPERATION
Filtered air from the air cleaner enters the intake
manifold through the throttle body. The throttle body
contains an air control passage controlled by an Idle
Air Control (IAC) motor. The air control passage is
used to supply air for idle conditions. A throttle valve
(plate) is used to supply air for above idle conditions.
Certain sensors are attached to the throttle body.
The accelerator pedal cable, speed control cable and
transmission control cable (when equipped) are con-
nected to the throttle body linkage arm.
A (factory adjusted) set screw is used to mechani-
cally limit the position of the throttle body throttle
plate.Never attempt to adjust the engine idle
speed using this screw.All idle speed functions are
controlled by the PCM.
Fig. 25 DOWNSTREAM 2/1 O2 SENSOR
Fig. 26 IAC MOTOR 2.4L
1 - Idle Air Control Motor
2 - Throttle Position Sensor
RSFUEL INJECTION14-33
O2 SENSOR (Continued)
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REMOVAL
(1) Disconnect negative cable from battery cable.
(2) Remove air inlet to throttle body hose clamp.
(3) Remove throttle and the speed control (if
equipped) cables from lever and bracket.
(4) Disconnect electrical connectors from the idle
air control motor and throttle position sensor (TPS)
(Fig. 26) or (Fig. 27).
(5) Remove throttle body to intake manifold
attaching bolts.
(6) Remove throttle body and gasket.
INSTALLATION
(1) Install a new gasket.
(2) Install throttle body.
(3) Tighten throttle body mounting bolts. The 2.4L
to 28.2 N´m (250  50 in. lbs.) torque, The 3.3/3.8L to
11.6 N´m (105  20 in. lbs.) torque.
(4) Connect electrical connectors to the idle air
control motor and throttle position sensor (TPS) (Fig.
26) or (Fig. 27).
(5) Install air inlet to throttle body hose clamp and
tighten.
(6) Connect negative cable to battery cable.
THROTTLE CONTROL CABLE
REMOVAL
(1) Working from the engine compartment, hold
the throttle body throttle lever in the wide open posi-
tion.
(2) Remove the throttle cable from the throttle
body cam.
(3) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft.
(4) Remove retainer clip from throttle cable and
grommet at dash panel.
(5) From the engine compartment, pull the throttle
cable and gromment out of the dash panel.
(6) Remove the throttle cable from throttle bracket
by carefully compressing both retaining ears simulta-
neously then gently pull the throttle cable from
throttle bracket or if it is the slide snap design you
have to slide the locking tab out of the hole and then
slide the cable assembly out of the bracket.
INSTALLATION
(1) From the engine compartment, push the hous-
ing end fitting and grommet into the dash panel.In-
stall gromment into the dash panel.
(2) Install the cable housing (throttle body end)
into the cable mounting bracket on the engine.
(3) From inside the vehicle, hold up the pedal and
install throttle cable and cable retainer in the upper
end of the pedal shaft.
(4) At the dash panel, install the cable retainer
clip between the end of the throttle cable fitting and
grommet
(5) From the engine compartment, rotate the
throttle lever wide open and install the throttle
cable.
Fig. 27 IAC MOTOR LOCATION 3.3/3.8L
1 - Idle Air Control Motor
2 - Throttle Position Sensor
14 - 34 FUEL INJECTIONRS
THROTTLE BODY (Continued)
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THROTTLE POSITION SENSOR
DESCRIPTION
The throttle position sensor mounts to the side of
the throttle body (Fig. 28) or (Fig. 29).The sensor
connects to the throttle blade shaft. The TPS is a
variable resistor that provides the Powertrain Con-
trol Module (PCM) with an input signal (voltage).
OPERATION
The signal represents throttle blade position. As
the position of the throttle blade changes, the resis-
tance 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 0.6 volt at minimum throttle
opening (idle) to a maximum of 4.5 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.
REMOVAL - 3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Remove the electrical connector from the Inlet
Air Temperature sensor.(3) Remove the air cleaner box lid. Remove hose
from throttle body.
(4) Disconnect the electrical connector at TPS.
(5) Disconnect the electrical connector at IAC.
(6) Remove the throttle and speed control cables
from throttle body.
(7) Remove 3 mounting bolts from throttle body.
(8) Remove throttle body.
(9) Disconnect the purge vacuum line from the
throttle body.
(10) Remove TPS from throttle body.
INSTALLATION - 3.3/3.8L
(1) Install TPS to throttle body.
(2) Disconnect the purge vacuum line from the
throttle body.
(3) Install throttle body.
(4) Install 3 mounting bolts from throttle body.
Tighten bolts.
(5) Install the throttle and speed control cables to
throttle body.
(6) Connect the electrical connector at TPS.
(7) Connect the electrical connector at IAC.
(8) Install the air cleaner box lid. Install hose to
throttle body.
(9) Install the electrical connector to the Inlet Air
Temperature sensor.
(10) Connect the negative battery cable.
Fig. 28 Throttle Position SensorÐ2.4L Engine
1 - Idle Air Control Motor
2 - Throttle Position Sensor
Fig. 29 Throttle Position SensorÐ3.3/3.8L Engine
1 - Idle Air Control Motor
2 - Throttle Position Sensor
RSFUEL INJECTION14-35
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FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL RAIL
DESCRIPTION..........................4
OPERATION............................4
REMOVAL - FUEL RAIL...................4
INSTALLATION - FUEL RAIL................5
FUEL FILTER / WATER SEPARATOR
DESCRIPTION..........................5
OPERATION............................5
FUEL LINES
DESCRIPTION
DESCRIPTION........................6
DESCRIPTION - HIGH PRESSURE FUEL
LINES...............................6OPERATION - HIGH PRESSURE FUEL LINES . . 6
DIAGNOSIS AND TESTING - HIGH
PRESSURE FUEL LINES.................6
FUEL TRANSFER PUMP
DESCRIPTION..........................7
OPERATION............................7
FUEL INJECTION PUMP
DESCRIPTION..........................7
REMOVAL.............................7
INSTALLATION..........................9
WATER IN FUEL SENSOR
DESCRIPTION.........................10
OPERATION...........................10
FUEL RAIL
DESCRIPTION
The fuel rail is mounted to the cylinder head cover/
intake manifold (Fig. 1).
OPERATION
The fuel rail stores the fuel for the injectors at
high pressure. At the same time, the pressure oscil-
lations which are generated due to the high-pressure
pump delivery and the injection of fuel are dampened
by the rail volume.
The fuel rail is common to all cylinders, hence it's
name ªcommon railº. Even when large quantities of
fuel are extracted, the fuel rail maintains a constant
inner pressure. This ensures that the injection pres-
sure remains constant from the moment the injector
opens.
REMOVAL - FUEL RAIL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Disconnect fuel injector high pressure lines.
(4) Disconnect fuel rail supply line. (Fig. 2)
(5) Disconnect fuel rail return line. (Fig. 2)
(6) Disconnect fuel rail high pressure sensor con-
nector. (Fig. 2)
(7) Remove engine electrical harness retainers
from the fuel rail retaining bolts/studs. (Fig. 2)
(8) Remove fuel rail retaining bolts and remove
fuel rail (Fig. 2).Fig. 1 ENGINE COMPONENT LOCATIONS
1 - FUEL INJECTOR RETURN LINE
2 - FUEL INJECTOR HIGH PRESSURE LINE
3 - OIL SEPARATOR
4 - FUEL INJECTOR
5 - CAMSHAFT POSITION SENSOR
6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
7 - EGR SOLENOID
8 - FUEL PRESSURE SENSOR
9 - CYLINDER HEAD COVER/INTAKE MANIFOLD
10 - FUEL RAIL
14a - 4 FUEL DELIVERYRG
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INSTALLATION - FUEL RAIL
(1) Install fuel rail to intake manifold/cylinder
head cover (Fig. 2). Torque retaining bolts to
27.5N´m.
(2) Install engine electrical harness retainers from
the fuel rail retaining bolts/studs. (Fig. 2)
(3) Connect fuel rail high pressure sensor electri-
cal connector. (Fig. 2)
(4) Connect fuel rail return line. (Fig. 2)
(5) Connect fuel rail supply line. (Fig. 2)
(6) Connect fuel injector high pressure lines. (Fig.
2)
(7) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(8) Connect negative battery cable.
FUEL FILTER / WATER
SEPARATOR
DESCRIPTION
The fuel filter/water separator assembly is located
under the vehicle in front of the rear axle assembly
(Fig. 3). The assembly also includes the fuel heater
and Water-In-Fuel (WIF) sensor.
OPERATION
The fuel filter/water separator protects the fuel
injection pump by removing water and contaminants
from the fuel. The construction of the filter/separator
allows fuel to pass through it, but helps prevent
moisture (water) from doing so. Moisture collects at
the bottom of the canister.
Fig. 2 FUEL RAIL COMPONENTS
1 - FUEL INJECTOR RETURN LINE
2 - FUEL INJECTOR HIGH PRESSURE LINE
3 - OIL SEPARATOR
4 - FUEL INJECTOR
5 - CAMSHAFT POSITION SENSOR
6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
7 - EGR SOLENOID
8 - FUEL PRESSURE SENSOR
9 - CYLINDER HEAD COVER/INTAKE MANIFOLD
10 - FUEL RAIL
Fig. 3 FUEL FILTER/WATER SEPARATOR
1 - LIFT PUMP RETAINING BOLTS
2 - LIFT PUMP
3 - FUEL FILTER/WATER SEPARATOR HOUSING
4 - FUEL HEATER
5 - CHECK BALL
6 - O-RING
7 - FLOW DIVERTER
8 - FUEL FILTER
9 - O-RING
10 - FUEL FILTER BOWL ASSEMBLY
RGFUEL DELIVERY14a-5
FUEL RAIL (Continued)
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CAUTION: The high-pressure fuel lines cannot con-
tact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. Only use the recommended
lines when replacement of high-pressure fuel line is
necessary.
FUEL TRANSFER PUMP
DESCRIPTION
The fuel transfer pump (fuel lift pump) is located
under the vehicle in front of the rear axle assembly
(Fig. 5). The 12±volt electric vane-type pump is oper-
ated and controlled by the Engine Control Module
(ECM).
OPERATION
The purpose of the fuel transfer pump is to supply
(transfer) a low-pressure fuel source:fromthe fuel
tank,throughthe fuel filter/water separator andto
the fuel injection pump. Here, the low-pressure is
raised to a high-pressure by the fuel injection pump
for operation of the high-pressure fuel injectors.
The fuel transfer pump is controlled by the Engine
Control Module(ECM). The ECM turns the fuel
transfer pump on for 30 seconds when the ignition
ket is turned ªONº.
With the ignition ªONº and fuel tranfer pump run-
ning, the low-pressure fuel pressure should be 13-17
psi.
FUEL INJECTION PUMP
DESCRIPTION
A radial-piston pump is used as the high pressure
pump for fuel pressure generation (Fig. 6).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL)
(3) Remove air cleaner housing assembly.
(4) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
Fig. 5 FUEL TRANSFER(LIFT) PUMP LOCATION
1 - LIFT PUMP RETAINING BOLTS
2 - LIFT PUMP
3 - FUEL FILTER/WATER SEPARATOR HOUSING
4 - FUEL HEATER
5 - CHECK BALL
6 - O-RING
7 - FLOW DIVERTER
8 - FUEL FILTER
9 - O-RING
10 - FUEL FILTER BOWL ASSEMBLY
Fig. 6 FUEL INJECTION PUMP
1 - FUEL INJECTION PUMP
2 - INJECTION PUMP PRESSURE SOLENOID
RGFUEL DELIVERY14a-7
FUEL LINES (Continued)
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