2002 CHRYSLER VOYAGER engine

FUEL INJECTION
TABLE OF CONTENTS
page page
FUEL INJECTOR
DESCRIPTION
FUEL INJECTOR......................11
OPERATION...........................11
REMOVAL.............................12
INSTALLATION.........................13
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL
REMOVAL - PEDAL POSITION SENSOR
(LHD)...............................14
REMOVAL - PEDAL POSITION SENSOR
(RHD)..............................14
INSTALLATION
INSTALLATION - PEDAL POSITION SENSOR
(LHD)...............................14
INSTALLATION - PEDAL POSITION SENSOR
(RHD)..............................14BOOST PRESSURE SENSOR
DESCRIPTION.........................14
OPERATION...........................14
DIAGNOSIS AND TESTING - BOOST
PRESSURE/INTAKE AIR TEMPERATURE
SENSOR............................14
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION.........................15
OPERATION...........................15
REMOVAL.............................15
INSTALLATION.........................15
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................15
OPERATION...........................15
MASS AIR FLOW (MAF) SENSOR
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
FUEL INJECTOR
DESCRIPTION
FUEL INJECTOR
There are individual fuel injectors for all four cyl-
inders. These fuel injectors are used to spray fuel
into the combustion chamber (Fig. 1).
OPERATION
The injector operation can be subdivided into four
operating states with the engine running and the
high-pressure pump generating pressure:
²Injector closed (with high pressure applied)
²Injector opens (start of injection)
²Injector opened fully
²Injector closes (end of injection)
Injector closed (with high pressure applied)
With the injector closed (at-rest state), the solenoid
valve is not energized and is therefore closed. With
the bleed orifice closed, the valve spring forces the
armature's ball onto the bleed-orifice seat. The rail's
high pressure build up in the valve control chamber,
and the same pressure is also present in the nozzle's
chamber volume. The rail pressure applied at the
control plunger's end face, together with the force of
Fig. 1 FUEL INJECTOR
1 - FUEL INJECTOR
2 - NOZZLE
3 - FUEL INLET FITTING
4 - ELECTRICAL CONNECTION
RGFUEL INJECTION14a-11
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the nozzle spring, maintain the nozzle in the closed
position against the opening forces applied to its
pressure stage (Fig. 2).
Injector opens (start of injection)
The solenoid valve is energized with the pickup
current which serves to ensure that it open quickly.The force exerted by the triggered solenoid now
exceeds that of the valve spring and the armature
opens the bleed orifice. Almost immediately, the high-
level pick-up current is reduced to the lower holding
current required for the electromagnet. This is possi-
ble due to the magnetic circuit's air gap now being
smaller. When the bleed orifice opens, fuel can flow
from the valve control chamber into the cavity situ-
ated above it, and from there via the fuel return to
the tank. The bleed orifice prevents complete pres-
sure balance, and the pressure in the valve control
chamber sinks as a result. This leads to the pressure
in the valve-control chamber being lower than that in
the nozzle's chamber volume which is still at the
same pressure level as the rail. The reduced pressure
in the valve-control chamber causes a reduction in
the force exerted on the control plunger, the nozzle
needle open as a result, and injection starts (Fig. 2).
Injector opens fully
The control plunger reaches its upper stop where it
remains supported by a cushion of fuel which is gen-
erated by the flow of fuel between the bleed and feed
orifices. The injector nozzle has now opened fully,
and the fuel is injected into the combustion chamber
at a pressure almost equal to that in the fuel rail
(Fig. 2).
Injector closes (end of injection)
As soon as the solenoid valve is no longer trig-
gered, the valve spring forces the armature down-
wards and the ball closes the bleed orifice. The
armature is a 2±piece design. Here, although the
armature plate is guided by a driver shoulder in its
downward movement, it can ªoverspringº with the
return spring so that it exerts no downwards-acting
forces on the armature and the ball. The closing of
the bleed orifice lead to pressure build up in the con-
trol chamber via the input from the feed orifice. This
pressure is the same as that in the rail and exerts an
increased force on the control plunger through its
end face. This force, together with that of the spring,
now exceeds the force exerted by the chamber volume
and the nozzle needle closes. Injection ceases as soon
as the nozzle needle comes up against its bottom stop
again (Fig. 2).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Disconnect injector electrical connector.
(4) Remove fuel return line from injector (Fig. 3).
(5) Remove fuel injector high pressure line (Fig. 3).
(6) Remove fuel injector retainer and retaining
bolt (Fig. 3).
Fig. 2 INJECTOR COMPONENTS
1 - INJECTOR CLOSED (AT-REST STATUS)
2 - ELECTRICAL CONNECTION
3 - TRIGGERING ELEMENT (SOLENOID VALVE)
4 - FUEL INLET (HIGH PRESSURE) FROM THE RAIL
5 - VALVE BALL
6 - BLEED ORIFICE
7 - FEED ORIFICE
8 - VALVE CONTROL CHAMBER
9 - VALVE CONTROL PLUNGER
10 - FEED PASSAGE TO THE NOZZLE
11 - NOZZLE NEEDLE
14a - 12 FUEL INJECTIONRG
FUEL INJECTOR (Continued)
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(7) Remove fuel injector from cylinder head (Fig.
3).
INSTALLATION
NOTE: Be sure the copper washer is installed on
end of injector before installing in cylinder head.
(1) Install fuel injector in cylinder head.(2) Install fuel injector retainer and bolt (Fig. 3).
Torque bolt to 32.4 N´m.
(3) Install fuel injector high pressure line (Fig. 3).
(4) Install fuel return line to injector (Fig. 3).
(5) Connect fuel injector electrical connector.
(6) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
(7) Connect negative battery cable.
ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
The accelerator pedal position sensor mounts to
the accelerator pedal bracket (Fig. 4).
OPERATION
The accelerator pedal position sensor contains a
potentiometer that is operated by the accelerator
pedal. As the accelerator pedal is depressed and
released, the sensor provides a variable voltage sig-
nal to the engine control module. This voltage signal
is directly proportional to accelerator pedal position.
When the pedal is fully depressed, the voltage signal
is high.
Fig. 3 FUEL SYSTEM COMPONENTS
1 - FUEL RAIL RETAINING BOLT
2 - FUEL RAIL RETAINING STUD
3 - FUEL RAIL RETURN LINE
4 - FUEL RAIL
5 - FUEL RAIL SUPPLY LINE
6 - IDLER PULLEY
7 - CRANKSHAFT PULLEY
8 - CRANKSHAFT PULLEY RETAINING BOLTS
9 - BELT TENSIONER RETAINING BOLT
10 - BELT TENSIONER
11 - FUEL INJECTOR RETAINER
12 - FUEL INJECTOR RETURN LINE
13 - FUEL INJECTOR RETAINING BOLT
14 - FUEL INJECTORS
15 - FUEL INJECTOR HIGH PRESSURE SUPPLY LINES
Fig. 4 ACCELERATOR PEDAL POSITION SENSOR
LOCATION (TYPICAL)
1 - ACCELERATOR PEDAL POSITION SENSOR ELECTRICAL
CONNECTOR
2 - ACCELERATOR PEDAL POSITION SENSOR
3 - ACCELERATOR PEDAL
4 - ACCELERATOR PEDAL MOUNTING BRACKET
RGFUEL INJECTION14a-13
FUEL INJECTOR (Continued)
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REMOVAL
REMOVAL - PEDAL POSITION SENSOR (LHD)
(1) Disconnect negative battery cable.
(2) Disconnect pedal position sensor electrical con-
nector (Fig. 4).
(3) Remove 2 pedal position sensor retaining nuts
(Fig. 4).
(4) Remove pedal position sensor from vehicle.
REMOVAL - PEDAL POSITION SENSOR (RHD)
(1) Disconnect negative battery cable.
(2) Disconnect pedal position sensor electrical con-
nector (Fig. 4).
(3) Remove 2 pedal position sensor retaining nuts
(Fig. 4).
(4) Remove pedal position sensor from vehicle.
INSTALLATION
INSTALLATION - PEDAL POSITION SENSOR
(LHD)
(1) Position pedal position sensor in vehicle.
(2) Install pedal position sensor retaining nuts
(Fig. 4).
(3) Connect pedal position sensor electrical connec-
tor (Fig. 4).
(4) Connect negative battery cable.
INSTALLATION - PEDAL POSITION SENSOR
(RHD)
(1) Position pedal position sensor in vehicle.
(2) Install 2 pedal position sensor retaining nuts
(Fig. 4).
(3) Connect pedal position sensor electrical connec-
tor (Fig. 4).
(4) Connect negative battery cable.
BOOST PRESSURE SENSOR
DESCRIPTION
The boost pressure/ intake air temperature sensor
is mounted to the top of the intake manifold. The
sensor allows the ECM to monitor air pressure
within the intake manifold. This sensor is also used
to monitor the intake air temperature (Fig. 5).
OPERATION
When the intake manifold pressure is low (high
vacuum) sensor voltage output is 0.25-1.8 volts at the
ECM. When the intake manifold pressure is high due
to turbo boost, sensor voltage output is 2.0-4.7 volts.
The sensor receives a 5-volts reference from the
ECM. Sensor ground is also provides by the ECM.
The ECM uses boost pressure combined with intake
air temerature to determine the volume of air enter-
ing the engine.
DIAGNOSIS AND TESTING - BOOST
PRESSURE/INTAKE AIR TEMPERATURE
SENSOR
If the boost pressure sensor fails, the ECM records
a DTC into memory and continues to operate the
engine in one of the three limp-in modes. When the
ECM is operating in this mode, a loss of power will
be present, as if the turbocharger was not operating.
The best method for diagnosing faults with the boost
pressure sensor is with the DRB IIItscan tool. Refer
to the Diesel Powertrain Diagnostic Manual for more
information.
Refer to On-Board Diagnostics in Emissions Con-
trol System for a list of Diagnostic Trouble Codes
(DTC's) for certain fuel system components.
Fig. 5 BOOST PRESSURE SENSOR/INTAKE AIR
TEMPERATURE SENSOR
14a - 14 FUEL INJECTIONRG
ACCELERATOR PEDAL POSITION SENSOR (Continued)
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INTAKE AIR TEMPERATURE
SENSOR
DESCRIPTION
The boost pressure sensor/intake air temperature
sensor is located in the top of the intake manifold
(Fig. 6). The intake air temperature sensor is used to
measure the intake air temperature. The intake air
temperture sensor is a dual purpose sensor. It is also
used as a boost pressure sensor.
OPERATION
The intake air temperature sensor is a negative
temperature coefficient (NTC) thermistor (resistance
varies inversly with temperature). This means at
cold air temperature its resistance is high, sothe volt-
age signal will be high. As intake air temperature
increases, sensor resistance decreases and the signal
voltage will be low. This allows the sensor to provide
an analog voltage signal (0.2-4.8 volts) to the ECM.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover retaining bolts and cover-
(Refer to 9 - ENGINE COVER - REMOVAL).(3) Disconnect intake air temperature electrical
connector.
(4) Remove intake air temperature sensor retain-
ing screws and sensor (Fig. 6).
INSTALLATION
(1) Install intake air temperature sensor and
retaining bolts (Fig. 6). Torque to 5.4 N´m.
(2) Connect intake air temperature sensor.
(3) Install engine cover and retaining bolts (Refer
to 9 - ENGINE COVER - INSTALLATION).
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
The crankshaft position sensor is mounted in the
right rear of the engine block below the turbocharger
(Fig. 7). This sensor is used to detect engine speed.
OPERATION
The crankshaft position sensor is a magnetic
pickup type sensor that generates an ac signal. The
sensor contains a permanent magent and a coil of
wire. The sensor generates an ac signal each time a
notch in the reluctor wheel on the crankshaft passes
across the permanent magnet. The ECM calculates
engine speed based on the frequency of the ac signal.
The ECM supplies the sensor ground.
Fig. 6 BOOST PRESSURE SENSOR/INTAKE AIR
TEMPERATURE SENSOR LOCATION
1 - FUEL RAIL
2 - FUEL PRESSURE SENSOR
3 - INTAKE AIR TEMPERATURE/BOOST PRESSURE SENSOR
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD
Fig. 7 CRANKSHAFT POSITION SENSOR
1 - CRANKSHAFT POSITION SENSOR
2 - CRANKSHAFT POSITION SENSOR ELECTRICAL
CONNECTOR
RGFUEL INJECTION14a-15
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MASS AIR FLOW (MAF)
SENSOR
DESCRIPTION
The Mass Air Flow (MAF) Sensor is mounted
inline in the air intake between the air filter and the
turbocharger (Fig. 8).
OPERATION
The ECM uses the mass air flow (MAF) sensor to
measure air density. The MAF sensor contains a
ceramic element. A signal voltage is provided to the
element. As engine speed increases, airflow across
the ceramic element increases. Changes in air flow
and air density cause the temperature of the ceramic
element to fluxuate. The ceramic element changes
resistance respectively to changes in temperature.
The change in resistance varies the signal voltage
output to the ECM. The diesel power relay supplies
battery power the to MAF sensor. Ground is providedby the ECM. The MAF sensor signal is provided by
the ECM.
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect MAF sensor electrical connector
(Fig. 9).
(3) Loosen MAF sensor retaining clamps (Fig. 9).
(4) Remove MAF sensor from airduct (Fig. 9).
INSTALLATION
(1) Install MAF sensor in airduct (Fig. 9).
(2) Tighten retaining clamps (Fig. 9).
(3) Connect MAF sensor electrical connector (Fig.
9).
(4) Connect negative battery cable.
Fig. 8 MASS AIR FLOW (MAF) SENSOR
Fig. 9 MASS AIR FLOW (MAF) SENSOR LOCATION
1 - MAF SENSOR ELECTRICAL CONNECTOR
2 - RETAINING CLAMPS
3 - MASS AIR FLOW (MAF) SENSOR
4 - AIR CLEANER HOUSING
14a - 16 FUEL INJECTIONRG
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STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION - POWER STEERING SYSTEM . . 1
OPERATION - POWER STEERING SYSTEM . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM FLOW AND
PRESSURE TEST......................1
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS............3SPECIFICATIONS
POWER STEERING FASTENER TORQUE . . . 9
SPECIAL TOOLS
POWER STEERING....................9
COLUMN..............................10
GEAR.................................26
PUMP.................................36
STEERING
DESCRIPTION - POWER STEERING SYSTEM
This vehicle comes with power steering as stan-
dard equipment. The power steering system consists
of these major components:
²POWER STEERING PUMP
²POWER STEERING GEAR
²POWER STEERING FLUID
²POWER STEERING FLUID COOLER
²POWER STEERING FLUID RESERVOIR
²POWER STEERING FLUID SUPPLY HOSE
²POWER STEERING FLUID PRESSURE HOSE
²POWER STEERING FLUID RETURN HOSE
For information on the first two components, refer
to their respective sections within this service man-
ual group. Information on all other components can
be found in POWER STEERING PUMP.
OPERATION - POWER STEERING SYSTEM
Turning of the steering wheel is converted into lin-
ear (side-to-side) travel through the meshing of the
helical pinion teeth with the rack teeth within the
steering gear. The lateral travel pushes and pulls the
tie rods to change the direction of the vehicle's front
wheels.
Power assist steering is provided by a belt driven
rotary type pump. It directs fluid through power
steering fluid hoses to the power steering gear where
it is used to assist the driver's turning effort.
Manual steering control of the vehicle can be main-
tained if power steering assist is lost. However,
under this condition, steering effort is significantly
increased.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM FLOW AND PRESSURE TEST
ALL ENGINES
The following procedure is to be used to test the
operation of the power steering system on this vehi-
cle. This test will provide the flow rate of the power
steering pump along with the maximum relief pres-
sure. This test is to be performed to determine if the
power steering pump or power steering gear is not
functioning properly. The following flow and pressure
test is performed using the Power Steering Analyzer
Kit, Special Tool 6815 (Fig. 1), hoses, Special Tools
6905 and 6959, and fittings from adapter kit, Special
Tool 6893.
Fig. 1 Power Steering Analyzer With Hoses Installed
1 - OUTLET
2 - SPECIAL TOOL 6815
3 - INLET
RSSTEERING19-1
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Assemble hoses on Power Steering Analyzer, Spe-
cial Tool 6815, as shown. Install Pressure Hose, Spe-
cial Tool 6905 (in 6893 kit), in the inlet fitting on
Power Steering Analyzer. Install Pressure Hose, Spe-
cial Tool 6713 (in 6815 kit) on Pressure Hose, Special
Tool 6905. Install Pressure Hose, Special Tool 6959,
in the outlet fitting on Power Steering Analyzer.
Install the following adapters from Adapter Set,
Special Tool 6893 (Fig. 2), on the analyzer hose ends:
Install Adapter Fitting, Special Tool 6844, on Pres-
sure Hose, Special Tool 6713. Install Adapter Fitting,
Special Tool 6826, on Pressure Hose, Special Tool
6959.
CAUTION: To prevent personal injury, safety gog-
gles should be worn at all times when performing
any test procedures on the power steering pump or
power steering gear.
The following procedure is to be used to test the
operation of the power steering system on the vehi-
cle.
(1) Check belt tension and adjust as necessary.
(2) Disconnect the power steering fluid pressure
hose from the power steering pump (Fig. 3) (Fig. 4).
(3) Connect Adapter Fitting, Special Tool 6844,
attached to pressure hose from inlet (gauge end) of
Power Steering Analyzer to the pressure fitting on
the power steering pump.
(4) Connect vehicle power steering fluid pressure
hose to Adapter Fitting, Special Tool 6826, which
should be already installed in the outlet hose (valve
end) of Power Steering Analyzer.NOTE: During the next few steps, do not steer vehi-
cle as air will be forced into the steering gear.
(5) Completely open valve on Power Steering Ana-
lyzer.
Fig. 2 Power Steering Analyzer Adapters 6893
Fig. 3 Pressure Hose Connection To Power Steering
Pump - 2.4L Engine
1 - POWER STEERING FLUID RETURN HOSE
2 - POWER STEERING PUMP
3 - POWER STEERING FLUID PRESSURE HOSE
Fig. 4 Supply & Pressure Hoses At Pump - 3.3L/3.8L
Engine
1 - PRESSURE HOSE AND FITTING
2 - SUPPLY HOSE AND CLAMP
3 - POWER STEERING PUMP
19 - 2 STEERINGRS
STEERING (Continued)
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