2002 CHRYSLER CARAVAN Service Manual

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Page 473 of 2399

CHRYSLER CARAVAN 2002 Service Manual FUSE BLOWN
(1) Verify condition of battery terminals and volt-
age, (Refer to 8 - ELECTRICAL/BATTERY SYSTEM
- DIAGNOSIS AND TESTING). If battery connec-
tions and battery charge is OK proceed to Step

FUSE BLOWN
(1) Verify condition of battery terminals and volt-
age, (Refer to 8 - ELECTRICAL/BATTERY SYSTEM
- DIAGNOSIS AND TESTING). If battery connec-
tions and battery charge is OK proceed to Step 2.
(2) Using a voltmeter, test for battery voltage at
both sides of horn fuse 7. If voltage is OK, on both
sides of fuse, proceed to Fuse OK. If voltage is OK,
on one side of fuse, the fuse is blown, proceed to Step
3.
(3) Using a suitable ammeter in place of the fuse,
test amperage draw of the horn circuit. If amperage
draw is greater than 20 amps without the horn
switch depressed, a grounded circuit exists between
the fuse and the horn relay. Proceed to Step 4. If
amperage draw is greater than 20 amps with the
horn switch depressed, a grounded circuit exists
between the horn relay and the horn. Proceed to step
Step 5.
(4) Remove the horn relay from the IPM. If the
amperage draw drops to 0 amps, the horn switch or
circuit is shorted. If the amperage draw does not
drop to 0 amps, repair short at the IPM.
(5) Disengage a wire connector from one of the
horns. If amperage drops and the connected horn
sounds, replace the faulty horn. If amperage does not
drop with both horns disconnected and the horn
switch depressed, proceed to Step 6.
(6) Using a continuity tester, with the horns dis-
connected test continuity of the X2 cavity of the horn
relay to ground. If continuity is detected, the circuit
is grounded between the Junction Block and the
horns. Locate and repair pinched harness.
FUSE OK
(1) Remove the horn relay from the intelligent
power module.
(2) Using a continuity tester, Depress horn switch
and test continuity from the X3 cavity of the horn
relay to ground.
(a) If continuity is detected, proceed to Step 3.
(b) If NO continuity, proceed to Step 4.
(3) Using a suitable jumper wire, jump across the
fuse F62 cavity and the X2 cavity of the horn relay in
the Junction Block.
(a) If the horn sounds, replace the horn relay.
(b) If the horn does not sound, proceed to Step 4.
(4) Remove airbag trim cover from steering wheel.
Refer to ELECTRICAL, RESTRAINTS.
(5) Test continuity across horn switch connectors
with horn switch depressed.
(a) If continuity is detected, repair open circuit
between the relay and the horn switch.(b) If NO continuity, replace airbag trim cover.
(6) Install horn relay into intelligent power mod-
ule.
(7) Disengage wire connectors from horns.
(8) Using a voltmeter, with the horn switch
depressed test voltage across horn connector termi-
nals of the wire harness (Fig. 1).
(a) If voltage is detected, replace horns.
(b) If NO voltage, proceed to step Step 9.
(9) With the horn switch depressed, test for volt-
age between the X2 circuit and ground.
(a) If voltage OK, repair system ground at right
cowl area.
(b) If NO voltage, repair open X2 circuit between
the relay and the horns.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Hoist and support the front of the vehicle on
safety stands.
(3) From behind the front fascia and forward of
the left front wheel, disconnect the wire connectors
from horn.
(4) Remove the mounting bracket attaching nut
from the bottom of radiator closure panel. Do not
remove the horn from mounting bracket.
(5) Separate the horn(s) from vehicle.
INSTALLATION
(1) Install the horns to the vehicle.
(2) Install the mounting bracket fastener.
(3) Reconnect the wire connectors to the horns.
(4) Lower the vehicle.
(5) Reconnect the battery negative cable.
Fig. 1 Horn Connector
8H - 4 HORNRS
HORN (Continued)
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CHRYSLER CARAVAN 2002 Service Manual HORN RELAY
DIAGNOSIS AND TESTING - HORN RELAY
(1) Remove horn relay.
(2) Using ohmmeter, test between relay connector
terminals 85 to 86 for 70 to 75 ohms resistance. If
resistance not OK, replace rel

Page 475 of 2399

CHRYSLER CARAVAN 2002 Service Manual ProCarManuals.com

Page 476 of 2399

CHRYSLER CARAVAN 2002 Service Manual IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION - IGNITION SYSTEM..........1
OPERATION - IGNITION SYSTEM...........1
SPECIFICATIONS
TORQUE.............................2
SPARK

IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION - IGNITION SYSTEM..........1
OPERATION - IGNITION SYSTEM...........1
SPECIFICATIONS
TORQUE.............................2
SPARK PLUG CABLE RESISTANCE........2
SPARK PLUG.........................2
FIRING ORDER........................3
AUTO SHUT DOWN RELAY
DESCRIPTION..........................3
OPERATION............................3
CAMSHAFT POSITION SENSOR
DESCRIPTION..........................3
OPERATION............................4
REMOVAL
REMOVAL - 2.4L.......................4
REMOVAL - 3.3/3.8L....................4
INSTALLATION
INSTALLATION - 2.4L...................6
INSTALLATION - 3.3/3.8L.................6
IGNITION COIL
DESCRIPTION..........................6
OPERATION............................6
REMOVAL
REMOVAL - 2.4L.......................7REMOVAL - 3.3/3.8L....................7
INSTALLATION
INSTALLATION - 2.4L...................7
INSTALLATION - 3.3/3.8L.................8
KNOCK SENSOR
DESCRIPTION..........................8
OPERATION............................8
REMOVAL
REMOVAL - 2.4L.......................8
REMOVAL - 3.8L.......................8
INSTALLATION
INSTALLATION - 2.4L...................8
INSTALLATION - 3.8L...................8
SPARK PLUG
DESCRIPTION
DESCRIPTION - STANDARD 4 CYLINDER . . . 9
DESCRIPTION - PLATINUM PLUGS........9
REMOVAL.............................9
INSTALLATION.........................10
SPARK PLUG CABLE
DESCRIPTION.........................10
REMOVAL.............................10
INSTALLATION.........................10
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.
RSIGNITION CONTROL8I-1
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CHRYSLER CARAVAN 2002 Service Manual SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
2.4L Target Magnet Screw 3 30
2.4L Camshaft Sensor
Screw12.9 115
3.3/3.8L Camshaft Sensor
Screw14.1 125
2.4L Ignition coil bolts 11.8 105
3.3/3

Page 478 of 2399

CHRYSLER CARAVAN 2002 Service Manual FIRING ORDERAUTO 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 ele

Page 479 of 2399

CHRYSLER CARAVAN 2002 Service Manual OPERATION
The camshaft position sensor provides cylinder
identification to the Powertrain Control Module
(PCM) (Fig. 1). The sensor generates pulses as
groups of notches on the camshaft sprocket pass

OPERATION
The camshaft position sensor provides cylinder
identification to the Powertrain Control Module
(PCM) (Fig. 1). The sensor generates pulses as
groups of notches on the camshaft sprocket pass
underneath it (Fig. 2). The PCM keeps track of
crankshaft rotation and identifies each cylinder by
the pulses generated by the notches on the camshaft
sprocket. 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. 2). 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 associatedwith the particular cylinder. The arrows and cylinder
call outs on (Fig. 2) represent which cylinder the flat
spot and notches identify, they do not indicate TDC
position.
REMOVAL
REMOVAL - 2.4L
The camshaft position sensor is mounted to the
rear of the cylinder head.
(1) Remove the negative battery cable.
(2) Disconnect electrical connectors from the cam-
shaft position sensor (Fig. 3).
(3) Remove camshaft position sensor mounting
screws. Remove sensor.
(4) Loosen screw attaching target magnet to rear
of camshaft and remove magnet (Fig. 4).
REMOVAL - 3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Remove the air box cover and inlet tube (Fig.
5).
(3) Disconnect camshaft position sensor electrical
connector from the wiring harness connector (Fig. 6).
(4) Remove bolt holding sensor.
(5) Rotate sensor away from block.
Fig. 1 Camshaft Position Sensor
1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
Fig. 2 Camshaft Sprocket
1 - CAMSHAFT SPROCKET
2 - CYL #6
3 - CYL #5
4 - CYL #4
5 - CYL #3
6 - CYL #2
7 - CYL #1
8I - 4 IGNITION CONTROLRS
CAMSHAFT POSITION SENSOR (Continued)
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Page 480 of 2399

CHRYSLER CARAVAN 2002 Service Manual (6) Pull sensor up out of the chain case cover.Do
not pull on the sensor wiring.There is an O-ring
on the body of the sensor. The O-ring may make
removal difficult. A light tap to top of sensor prior

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