2002 CHRYSLER VOYAGER Camshaft sensor

(4) Remove the screw holding the PLG control
module to the D-pillar (Fig. 10).
(5) Remove the PLG control module from the vehi-
cle.
INSTALLATION
(1) Install the PLG control module on the D-pillar
and install retaining screw. Torque the screw to 14.5
in. lbs.
(2) Connect the wire harness connections on the
PLG control module. Be certain to slide connector
locks to the locked position.
(3) Install the D-pillar trim panel on the vehicle.
Refer to the Body section for the procedure.
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any PLG control module diagnostic trouble
codes.
(6) Verify PLG system operation. Cycle the PLG
through one complete open and close cycle, this will
allow the PLG control module to relearn its cycle
with the new components.
POWERTRAIN CONTROL
MODULE
DESCRIPTION
DESCRIPTION
The Powertrain Control Module (PCM) is a digital
computer containing a microprocessor (Fig. 11). The
PCM receives input signals from various switches
and sensors referred to as Powertrain Control Mod-
ule Inputs. Based on these inputs, the PCM adjusts
various engine and vehicle operations through
devices referred to as Powertrain Control Module
Outputs.
NOTE: PCM Inputs:
²Air Conditioning Pressure Transducer
²ASD Relay
²Battery Voltage
²Brake Switch
²Camshaft Position Sensor
²Crankshaft Position Sensor
²Distance Sensor (from transmission control mod-
ule)
²EGR Position Feedback
²Engine Coolant Temperature Sensor
²Heated Oxygen Sensors
Fig. 10 LIFTGATE CONTROL MODULE
1 - POWER LIFTGATE CONTROL MODULE
2 - MODULE RETAINING SCREWS
3 - D-PILLAR
4 - POWER LIFTGATE MOTOR
5 - MODULE ELECTRICAL CONNECTORS
Fig. 11 Powertrain Control Module (PCM)
1 - Battery
2 - Power Distribution Center
3 - Powertrain Control Module
RSELECTRONIC CONTROL MODULES8E-11
POWER LIFTGATE MODULE (Continued)
ProCarManuals.com

²Ignition sense
²Intake Air Temperature Sensor
²Knock Sensor
²Leak Detection Pump Feedback
²Manifold Absolute Pressure (MAP) Sensor
²Park/Neutral (from transmission control module)
²PCI Bus
²Power Steering Pressure Switch
²Proportional Purge Sense
²SCI Receive
²Speed Control
²Throttle Position Sensor
²Torque Management Input (From TCM)
²Transaxle Control Module (TCM)
²Transaxle Gear Engagement (From TCM)
²Vehicle Speed (from transmission control mod-
ule)
NOTE: PCM Outputs:
²Air Conditioning Clutch Relay
²Automatic Shut Down (ASD) and Fuel Pump
Relays
²Data Link Connector (PCI and SCI Transmit)
²Double Start Override
²EGR Solenoid
²Fuel Injectors
²Generator Field
²High Speed Fan Relay
²Idle Air Control Motor
²Ignition Coils
²Leak Detection Pump
²Low Speed Fan Relay
²MTV Actuator
²Proportional Purge Solenoid
²SRV Valve
²Speed Control Relay
²Speed Control Vent Relay
²Speed Control Vacuum Relay
²8 Volt Output
²5 Volt Output
Based on inputs it receives, the powertrain control
module (PCM) adjusts fuel injector pulse width, idle
speed, ignition timing, and canister purge operation.
The PCM regulates the cooling fans, air conditioning
and speed control systems. The PCM changes gener-
ator charge rate by adjusting the generator field.
The PCM adjusts injector pulse width (air-fuel
ratio) based on the following inputs.
²Battery Voltage
²Intake Air Temperature Sensor
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)²Exhaust Gas Oxygen Content (heated oxygen
sensors)
²Manifold Absolute Pressure
²Throttle Position
The PCM adjusts engine idle speed through the
idle air control motor based on the following inputs.
²Brake Switch
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Park/Neutral (transmission gear selection)
²Transaxle Gear Engagement
²Throttle Position
²Vehicle Speed (from Transmission Control Mod-
ule)
The PCM adjusts ignition timing based on the fol-
lowing inputs.
²Intake Air Temperature
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Knock Sensor
²Manifold Absolute Pressure
²Park/Neutral (transmission gear selection)
²Transaxle Gear Engagement
²Throttle Position
The automatic shut down (ASD) and fuel pump
relays are mounted externally, but turned on and off
by the powertrain control module through the same
circuit.
The camshaft and crankshaft signals are sent to
the powertrain control module. If the PCM does not
receive both signals within approximately one second
of engine cranking, it deactivates the ASD and fuel
pump relays. When these relays are deactivated,
power is shut off to the fuel injectors, ignition coils,
fuel pump and the heating element in each oxygen
sensor.
The PCM contains a voltage converter that
changes battery voltage to a regulated 8.0 volts. The
8.0 volts power the camshaft position sensor, crank-
shaft position sensor and vehicle speed sensor. The
PCM also provides a 5.0 volts supply for the engine
coolant temperature sensor, intake air temperature
sensor, manifold absolute pressure sensor and throt-
tle position sensor.
The PCM engine control strategy prevents reduced
idle speeds until after the engine operates for 320 km
(200 miles). If the PCM is replaced after 320 km (200
miles) of usage, update the mileage in new PCM. Use
the DRB scan tool to change the mileage in the PCM.
Refer to the appropriate Powertrain Diagnostic Man-
ual and the DRB scan tool.
8E - 12 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

DIAGNOSTIC TROUBLE CODE
DESCRIPTION
A Diagnostic Trouble Code (DTC) indicates the
PCM has recognized an abnormal condition in the
system.Remember that DTC's are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
NOTE: For a list of DTC's, refer to the charts in this
section.
(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC
SCAN TOOL
CODEDRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
P0016 Crankshaft/Camshaft Timing
MisalignmentA rationality error has been detected for camshaft position
out of phase with crankshaft
P0030 O2 sensor 1/1 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0031 O2 sensor 1/1 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0036 O2 sensor 1/2 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0037 O2 sensor 1/2 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0038 O2 sensor 1/2 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0043 O2 sensor 1/3 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0044 O2 sensor 1/3 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0050 O2 sensor 2/1 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0051 O2 sensor 2/1 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0052 O2 sensor 2/1 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0056 O2 sensor 2/1 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0057 O2 sensor 2/2 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0058 O2 sensor 2/2 Heater Circuit Shorted condition detected in the oxygen sensor heater
element control feedback sense circuit.
P0068 Manifold Pressure/Throttle Position
CorrelationMAP sensor signal does not correlate to throttle position
sensor signal. Possible vacuum leak.
P0070 Ambient Temp Sensor Stuck A rationality error has been detected in the ambient temp.
sensor test.
P0071 (M) Ambient Temp Sensor Performance Ambient change less than 3É C in 200 Miles
P0072 Ambient Temp Sensor Low Ambient temp. sensor input below the minimum acceptable
voltage
P0073 Ambient Temp Sensor High Ambient temp. sensor input above the maximum acceptable
voltage
RSELECTRONIC CONTROL MODULES8E-13
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC
SCAN TOOL
CODEDRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
P0330 Knock Sensor #2 Circuit Knock sensor (#2) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
P0335 Crankshaft Position Sensor Circuit A rationality error has been detected for loss of crankshaft
position sensor.
P0339 Crankshaft Position Sensor Circuit
IntermittentA rationality error has been detected for intermittent loss of
crankshaft position sensor.
P0340 (M) Camshaft Position Sensor Circuit A rationality error has been detected for loss of camshaft
position sensor.
P0344 Camshaft Position Sensor Circuit
IntermittentA rationality error has been detected for intermittent loss of
camshaft position sensor.
P0350 Ignition Coil Draws Too Much Current A coil (1-5) is drawing too much current.
P0351 (M) Ignition Coil Primary # 1 Circuit Peak primary circuit current not achieved with maximum
dwell time.
P0352 (M) Ignition Coil Primary # 2 Circuit Peak primary circuit current not achieved with maximum
dwell time.
P0353 (M) Ignition Coil Primary # 3 Circuit Peak primary circuit current not achieved with maximum
dwell time.
P0354 (M) Ignition Coil Primary# 4 Circuit Peak primary circuit current not achieved with maximum
dwell time (High Impedance).
P0355 (M) Ignition Coil Primary # 5 Circuit Peak primary circuit current not achieved with maximum
dwell time (High Impedance).
P0356 (M) Ignition Coil Primary # 6 Circuit Peak primary circuit current not achieved with maximum
dwell time (high impedance).
P0357 Ignition Coil Primary # 7 Circuit Peak primary circuit current not achieved with maximum
dwell time (high impedance).
P0358 Ignition Coil Primary # 8 Circuit Peak primary circuit current not achieved with maximum
dwell time (high impedance).
P0400 Diesel EGR System Failure
P0401 (M) EGR System Failure Required change in air/fuel ration not detected during
diagnostic test.
P0403 (M) EGR Solenoid Circuit An open or shorted condition detected in the EGR solenoid
control circuit.
P0404 (M) EGR Position Sensor Rationality EGR position sensor signal does not correlate to EGR duty
cycle.
P0405 (M) EGR Position Sensor Volts Too Low EGR position sensor input below the acceptable voltage
range.
P0406 (M) EGR Position Sensor Volts Too High EGR position sensor input above the acceptable voltage
range.
P0412 Secondary Air Solenoid Circuit An open or shorted condition detected in the secondary air
(air switching/aspirator) solenoid control circuit.
P0420 (M) 1/1 Catalytic Converter Efficiency Catalyst 1/1 efficiency below required level.
P0432 (M) 1/2 Catalytic Converter Efficiency Catalyst 2/1 efficiency below required level.
P0440 General EVAP System Failure General system failure.
RSELECTRONIC CONTROL MODULES8E-17
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC
SCAN TOOL
CODEDRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
P2008 Short Runner Valve Solenoid Circuit An open or shorted condition detected in the short runner
tuning valve control circuit.
P2302 Ignition Coil Secondary #1 Circuit
P2305 Ignition Coil Secondary #2 Circuit
P2308 Ignition Coil Secondary #3 Circuit
P2311 Ignition Coil Secondary #4 Circuit
P2314 Ignition Coil Secondary #5 Circuit
P2317 Ignition Coil Secondary #6 Circuit
P2320 Ignition Coil Secondary #7 Circuit
P2323 Ignition Coil Secondary #8 Circuit
P2503 Charging System Voltage Low Charging system voltage below minimum acceptable voltage.
OPERATION - SENSOR RETURN - PCM INPUT
The sensor return circuit provides a low electrical
noise ground reference for all of the systems sensors.
The sensor return circuit connects to internal ground
circuits within the Powertrain Control Module (PCM).
OPERATION - SCI RECEIVE - PCM INPUT
SCI Receive is the serial data communication
receive circuit for the DRB scan tool. The Powertrain
Control Module (PCM) receives data from the DRB
through the SCI Receive circuit.
OPERATION - IGNITION SENSE - PCM INPUT
The ignition sense input informs the Powertrain
Control Module (PCM) that the ignition switch is in
the crank or run position.
OPERATION - PCM GROUND
Ground is provided through multiple pins of the
PCM connector. Depending on the vehicle there may
be as many as three different ground pins. There are
power grounds and sensor grounds.
The power grounds are used to control the ground
side of any relay, solenoid, ignition coil or injector.
The signal ground is used for any input that uses
sensor return for ground, and the ground side of any
internal processing component.
The SBEC III case is shielded to prevent RFI and
EMI. The PCM case is grounded and must be firmly
attached to a good, clean body ground.
Internally all grounds are connected together, how-
ever there is noise suppression on the sensor ground.
For EMI and RFI protection the case is also
grounded separately from the ground pins.
OPERATION
OPERATION - 8-VOLT SUPPLY - PCM OUTPUT
The PCM supplies 8 volts to the crankshaft posi-
tion sensor, camshaft position sensor.
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT
The PCM supplies 5 volts to the following sensors:
²A/C pressure transducer
²Engine coolant temperature sensor
²Manifold absolute pressure sensor
²Throttle position sensor
²Linear EGR solenoid
²Battery temperature
²Knock sensor
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES
BULB CHECK
Key on: Bulb illuminated until vehicle starts, as
long as all once per trip (readiness) monitors com-
pleted. If monitors havenotbeen completed, then:
Key on: bulb check for about 8 seconds, lamp then
flashes if once per trip (readiness) monitors havenot
been completed until vehicle is started, then MIL is
extinguished.
OBTAINING DTC'S USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
RSELECTRONIC CONTROL MODULES8E-25
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

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
ProCarManuals.com

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
3.3/3.8LIgnition coil bolts 11.8 105
Spark Plugs 17.5 13
Knock Sensor 10 7
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 RE14PLP5 0.048 TO 0.053 14mm (1 in.) reach
3.8L RE14PLP5 0.048 TO 0.053 14mm (1 in. ) reach
8I - 2 IGNITION CONTROLRS
IGNITION CONTROL (Continued)
ProCarManuals.com

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 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.
When energized, the ASD relay provides power to
operate the injectors, ignition coil, generator field, O2
sensor heaters (both upstream and downstream),
(EGR solenoid and PCV heater if equipped) and also
provides a sense circuit to the PCM for diagnostic
purposes. If the PCM does not receive 12 volts from
this input after grounding the ASD relay, it sets a
Diagnostic Trouble Code (DTC). The PCM energizes
the ASD any time there is a Crankshaft Position sen-
sor 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. 6)
and the camshaft position sensor for the 2.4L is
mounted on the end of the cylinder head (Fig. 3).
FIRING ORDER 2.4L
Firing Order 1-2-3-4-5-6 3.3/3.8L
1 - Electrical Connector
RSIGNITION CONTROL8I-3
IGNITION CONTROL (Continued)
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