2003 CHRYSLER CARAVAN ignition

cator illuminates. When the switch rocker is moved
to its neutral position (middle), Off is selected and
both LED indicators are extinguished.
Each switch provides separate resistor multiplexed
hard wire inputs to its respective Heated Seat Mod-
ule (HSM) to indicate the selected switch position.
The heated seat module responds to the heated seat
switch status messages by controlling the output to
the seat heater elements of the selected seat. The
Low heat position set point is about 36É C (97É F),
and the High heat position set point is about 41É C
(105É F).
DIAGNOSIS AND TESTING - DRIVER HEATED
SEAT SWITCH
For complete circuit diagrams, refer toWiring
Diagrams.
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, SEAT OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CHECKING SWITCH SIGNAL AND WIRING AT THE
MODULE
(1) Disconnect and isolate the battery negative
cable.
(2) Access and disconnect the gray 4-way connector
from the heated seat module. Visually inspect wiring
terminals for damage that would prevent positive
connection. If not OK, repair or replace the necessary
components.
(3) Place the heated seat switch in the LO posi-
tion. Using an Ohmmeter, check the resistance
between cavities 2 and 3 of the gray connector noted
above. Resistance should be about 3.5 kilohms (3500
ohms). If not OK, check resistance directly at switch,
as noted below. If OK, proceed to the next step. If not
OK, replace the faulty switch.
(4) Place the heated seat switch in the HI position.
Using an ohmmeter, check the resistance between
cavities 2 and 3 of the gray connector noted above.
Resistance should be about 1.4 kilohms (1400 ohms).
If not OK, check resistance directly at switch, as
noted below. If OK, proceed. If not OK replace the
faulty switch.
(5) With the system ON in the HI position, check
for battery voltage and ground at cavities 4 and 1. If
OK, proceed with testing remaining components. If
not OK, repair open or shorted wiring.
CHECKING SWITCH ONLY
(1) Disconnect and isolate the battery negative
cable. Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - REMOV-
AL). Check for continuity between the ground circuit
cavity (#10) of the instrument panel switch bank
electrical connector and a good ground. There should
be continuity. If OK, go to Step 2. If not OK, repair
the open ground circuit to ground as required.
(2) Reconnect the battery negative cable. Turn the
ignition switch to the On position. Check for battery
voltage at the fused ignition switch output (run) cir-
cuit cavity of the instrument panel switch bank con-
nector (#4). If OK, turn the ignition switch to the Off
position, and go to Step 3. If not OK, repair the open
fused ignition switch output (run) circuit as required.
(3) Test the heated seat switch as shown in the
Heated Seat Switch Test chart and the connector pin-
out below (Fig. 3). If OK, go to Step 4. If not OK,
replace the faulty switch bank assembly.
DRIVER HEATED SEAT SWITCH TEST
SWITCH
POSITIONRESISTANCE
BETWEENRESISTANCE
(OHMS)
Off Pin4&5OPEN
Low Pin4&53570
High Pin4&51430
All resistance values are  1%.
Fig. 3 Instrument Panel Switch Bank Connector
RSHEATED SEAT SYSTEM8G-9
DRIVER HEATED SEAT SWITCH (Continued)
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cator illuminates. When the switch rocker is moved
to its neutral position (middle), Off is selected and
both LED indicators are extinguished.
Each switch provides separate resistor multiplexed
hard wire inputs to its respective Heated Seat Mod-
ule (HSM) to indicate the selected switch position.
The heated seat module responds to the heated seat
switch status messages by controlling the output to
the seat heater elements of the selected seat. The
Low heat position set point is about 36É C (97É F),
and the High heat position set point is about 41É C
(105É F).
DIAGNOSIS AND TESTING - PASSENGER
HEATED SEAT SWITCH
For complete circuit diagrams, refer toWiring
Diagrams.
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, SEAT OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CHECKING SWITCH SIGNAL AND WIRING AT THE
MODULE
(1) Disconnect and isolate the battery negative
cable.
(2) Access and disconnect the gray 4-way connector
from the heated seat module. Visually inspect wiring
terminals for damage that would prevent positive
connection. If not OK, repair or replace the necessary
components.
(3) Reconnect the negative battery cable and Turn
heated seat ON in the LO position. Using an Ohm-
meter, check the resistance between cavities 2 and 3
of the gray connector noted above. Resistance should
be about 3.5 kiloohms (3500 ohms). If not OK, check
resistance directly at switch, as noted below. If OK,
proceed. If NOT OK replace the switch or faulty wir-
ing.
(4) Turn heated seat ON in the HI position. Using
an Ohmmeter, check the resistance between cavities
2 and 3 of the gray connector noted above. Resistance
should be about 1.4 kiloohms (1400 ohms). If not OK,
check resistance directly at switch, as noted below. If
OK, proceed. If NOT OK replace the switch or faulty
wiring.
(5) With the system ON in the HI position, Check
for battery voltage and ground at cavities 4 and 1. If
OK, proceed with testing remaining components. If
NOT OK, repair open or wiring short.
CHECKING SWITCH ONLY
(1) Disconnect and isolate the battery negative
cable. Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - REMOV-
AL). Check for continuity between the ground circuit
cavity (#10) of the instrument panel switch bank
electrical connector and a good ground. There should
be continuity. If OK, go to Step 2. If not OK, repair
the open ground circuit to ground as required.
(2) Reconnect the battery negative cable. Turn the
ignition switch to the On position. Check for battery
voltage at the fused ignition switch output (run) cir-
cuit cavity of the instrument panel switch bank con-
nector (#4). If OK, turn the ignition switch to the Off
position, and go to Step 3. If not OK, repair the open
fused ignition switch output (run) circuit as required.
(3) Test the heated seat switch as shown in the
Heated Seat Switch Test chart and the connector pin-
out below (Fig. 7). If OK, go to Step 4. If not OK,
replace the faulty switch bank assembly.
PASSENGER HEATED SEAT SWITCH TEST
SWITCH
POSITIONRESISTANCE
BETWEENRESISTANCE
(OHMS)
Off Pin3&4OPEN
Low Pin3&43570
High Pin3&41430
All resistance values are  1%.
Fig. 7 Instrument Panel Switch Bank Connector
RSHEATED SEAT SYSTEM8G-13
PASSENGER HEATED SEAT SWITCH (Continued)
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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............................3
REMOVAL
REMOVAL - 2.4L.......................4
REMOVAL - 3.3/3.8L....................5
INSTALLATION
INSTALLATION - 2.4L...................5
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.................7
KNOCK SENSOR
DESCRIPTION..........................8
OPERATION............................8
REMOVAL
REMOVAL - 2.4L.......................8
REMOVAL - 3.8L.......................8
INSTALLATION
INSTALLATION - 2.4L...................8
INSTALLATION - 3.8L...................9
SPARK PLUG
DESCRIPTION
DESCRIPTION - STANDARD 4 CYLINDER . . . 9
DESCRIPTION - PLATINUM PLUGS........9
REMOVAL.............................10
INSTALLATION.........................10
SPARK PLUG CABLE
DESCRIPTION.........................10
REMOVAL - 2.0/2.4L.....................10
INSTALLATION - 2.0/2.4L.................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. If equipped with the coil on plug ignition
system it utilizes an 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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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)
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FIRING ORDER
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 (SBEC vehicles) or the
engine switched battery (NGC vehicles) informs the
PCM when the ASD relay energizes. A 12 volt signal
at this input indicates to the PCM that the ASD has
been activated. This input is also used to power cer-
tain drivers on NGC vehicles.
When energized, the ASD relay on SBEC vehicles
supplies battery voltage to the fuel injectors, ignition
coils and the heating element in each oxygen sensor.
When energized, the ASD relay on NGC vehicles
provides power to operate the injectors, ignition coil,
generator field, O2 sensor heaters (both upstream
and downstream), evaporative purge solenoid, EGR
solenoid (if equipped) wastegate solenoid (if
equipped), and NVLD solenoid (if equipped).
For both SBEC and NGC vehicles, the ASD relay
also provides a sense circuit to the PCM for diagnos-
tic purposes. If the PCM does not receive 12 volts
from this input after grounding the control side of
the ASD relay, it sets a Diagnostic Trouble Code
(DTC). The PCM energizes the ASD any time there is
an engine speed that exceeds a predetermined value
(typically about 50 rpm). The ASD relay can also be
energized after the engine has been turned off to per-
form 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 for
SBEC vehicles. On NGC vehicles it checks the O2
heater upon vehicle start. The PCM still operates
internally to perform several checks, including moni-
toring the O2 sensor heaters.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
The camshaft position sensor for 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).
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.
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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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 sen-
sor. 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 (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).
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
Fig. 3 EGR/CAM SENSOR 2.4L
8I - 4 IGNITION CONTROLRS
CAMSHAFT POSITION SENSOR (Continued)
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(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.
(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 to
removal may reduce force needed for removal.
INSTALLATION
INSTALLATION - 2.4L
The target magnet has locating dowels that fit into
machined locating holes in the end of the camshaft
(Fig. 7).
Fig. 4 Target Magnet Removal/Installation
1 - TARGET MAGNET
2 - MOUNTING BOLT
3 - REAR OF CYLINDER HEAD
Fig. 5 AIR BOX COVER
Fig. 6 CAMSHAFT POSITION SENSOR
Fig. 7 Target Magnet Installation
1 - LOCATING DOWELS
2 - LOCATING HOLES (2)
RSIGNITION CONTROL8I-5
CAMSHAFT POSITION SENSOR (Continued)
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(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.
(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.
8).
(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. 5).
(6) Connect the negative battery cable.
IGNITION COIL
DESCRIPTION
The ignition coil assembly consists of 2 or 3 inde-
pendent coils molded together (Fig. 9) or (Fig. 10).
The coil assembly for the 3.3/3.8L is mounted on the
intake manifold. The coil assembly for the 2.4L is
mounted on the cylinder head cover. Spark plug
cables route to each cylinder from the coil.
OPERATION
The coil fires two spark plugs every power stroke.
One plug is the cylinder under compression, the
other cylinder fires on the exhaust stroke. The Pow-
ertrain Control Module (PCM) determines which of
the coils to charge and fire at the correct time.
The Auto Shutdown (ASD) relay provides battery
voltage to the ignition coil. The PCM provides a
ground contact (circuit) for energizing the coil. When
the PCM breaks the contact, the magnetic energy in
the coil transfers to the secondary causing the spark.
The PCM will de-energize the ASD relay if it does
not receive the crankshaft position sensor and cam-
shaft position sensor inputs. Refer to Auto Shutdown
(ASD) RelayÐPCM Output, in this section for relay
operation.
Fig. 8 Camshaft Position Sensor and Spacer
1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
Fig. 9 IGNITION COIL - 2.4L
8I - 6 IGNITION CONTROLRS
CAMSHAFT POSITION SENSOR (Continued)
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