2003 CHRYSLER VOYAGER cam sensor

POWERTRAIN CONTROL MODULE C1 (SBEC) - GRAY/BLACK 40 WAY
CAV CIRCUIT FUNCTION
1- -
2 K18 16DB/OR IGNITION COIL NO. 3 DRIVER
3 K17 16DB/TN IGNITION COIL NO. 2 DRIVER
4- -
5 V32 18VT/YL SPEED CONTROL ON/OFF SWITCH SENSE
6 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT
7 K13 16BR/LB FUEL INJECTOR NO. 3 DRIVER
8 K20 18BR/GY GENERATOR FIELD CONTROL
9- -
10 Z130 18BK/BR GROUND
11 K19 16DB/DG IGNITION COIL NO. 1 DRIVER
12 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE
13 K11 16BR/YL FUEL INJECTOR NO. 1 DRIVER
14 K58 16BR/VT FUEL INJECTOR NO. 6 DRIVER
15 K38 16BR/OR FUEL INJECTOR NO. 5 DRIVER
16 K14 16BR/TN FUEL INJECTOR NO. 4 DRIVER
17 K12 16BR/DB FUEL INJECTOR NO. 2 DRIVER
18 K99 18BR/LG OXYGEN SENSOR 1/1 HEATER CONTROL
19 - -
20 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
21 - -
22 - -
23 - -
24 - -
25 K42 18DB/YL (ABS EXCEPT EXPORT) KNOCK SENSOR SIGNAL
26 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
27 K902 18BR/DG OXYGEN SENSOR GROUND
28 - -
29 - -
30 K41 18DB/LB OXYGEN SENSOR 1/1 SIGNAL
31 T752 18DG/OR STARTER MOTOR RELAY CONTROL
32 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
33 K44 18DB/GY CAMSHAFT POSITION SENSOR SIGNAL
34 - -
35 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
36 K1 18VT/BR MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
37 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
38 T751 18YL FUSED IGNITION SWITCH OUTPUT (START)
39 - -
40 K35 18DB/VT EGR SOLENOID CONTROL
8W - 80 - 106 8W-80 CONNECTOR PIN-OUTSRS
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C317 BK Right Sliding Door 31
C318 (Trailer Tow) BK Left Quarter N/S
C319 Left Side Liftgate N/S
C320 DKGY Driver Power Seat on Seat Harness N/S
C321 DKGY Under Passenger Seat N/S
C322 BK On Seat Harness to Body 31
C324 BK Left Sliding Door N/S
C325 BK Right Sliding Door 31
C326 YL At Driver Side Airbag N/S
C327 YL At Passenger Side Airbag N/S
C328 Front of Left Quarter 46
C329 (Diesel) BK Near Fuel Tank 33
C330 (Diesel) LTGY Left Rear Engine Compartment N/S
C331 (Diesel) BK Left Rear Engine Compartment N/S
Cabin Heater RHD) At Heater N/S
Cabin Heater Assist C1 (Diesel) BK Top of Engine 15, 16
Cabin Heater Assist C2 (Diesel) BK Top of Engine 15, 16
Camshaft Position Sensor (Gas) BK Rear of Cylinder Head
Right Side of Engine11
Camshaft Position Sensor
(Diesel)BK Rear of Cylinder Head 15, 16
CD Changer Behind CD Changer N/S
Center Dome Lamp GY At Lamp N/S
Center High Mounted Stop Lamp BK At Lamp 48
Clockspring - C1 WT Steering Column 19, 20, 21, 22, 30
Clockspring - C2 YL Steering Column 19, 20, 21, 22, 30
Clockspring - C3 BK Steering Column N/S
Clockspring - C4 BK Steering Column N/S
Clockspring - C5 YL Steering Column N/S
Clutch Pedal Interlock Switch
(Diesel)RD At Switch/Driver Side 41
Clutch Pedal Upstop Switch
(Diesel)BK At Switch/Driver Side 41
Controller Anti-Lock Brake BK Right Side of Engine Compartment 11, 16, 17, 18
Crank Case Ventilation Heater
(Diesel)BK Top of Cylinder Head 15
Crankshaft Position Sensor
(Diesel)BK Rear of Engine 16
Crankshaft Position Sensor (Gas) BK Rear of Engine 13, 17
Data Link Connector WT Lower Instrument Panel Near
Steering Column40, 41
Dosing Pump BK Top of Engine N/S
Driver Airbag Squib1 BN Steering Column N/S
Driver Airbag Squib2 BK Steering Column N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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AIR CLEANER ELEMENT
REMOVAL
(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and
remove cover tabs from air box.
(3) Lift cover and remove the element (Fig. 11).
INSTALLATION
(1) Install the air filter element into air box (Fig.
11).
(2) Move cover so that the tabs insert into the air
box.
(3) Push cover down and snap the 2 clips.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor
(Fig. 12).
(3) Remove the inlet hose to throttle body (Fig. 11).
(4) Remove the bolt for air box at upper radiator
cross member.
(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
12).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head
contains dual over-head camshafts with four valves
per cylinder (Fig. 13). The valves are arranged in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.
Integral oil galleries provide lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
Fig. 11 AIR BOX COVER
Fig. 12 IAT SENSOR 2.4L
9 - 24 ENGINE 2.4LRS
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²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from intake manifold water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump reservoir and
line support bracket from lower intake manifold and
set aside. Do not disconnect lines.
(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-
ing connectors.
(13) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(14) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-25
CYLINDER HEAD (Continued)
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(2) Position cylinder head gasket on engine block
(Fig. 18).
(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence
shown in (Fig. 19). Using the 4 step torque turn
method, tighten according to the following values:
²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)(8) Install timing belt rear cover and timing belt
idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(10) Connect cam sensor and fuel injectors wiring
connectors.
(11) Install ignition coil and wires. Connect igni-
tion coil wiring connector.
(12) Install power steering pump reservoir and
line support bracket to cylinder head.
(13) Raise vehicle and install the exhaust pipe to
the manifold.
(14) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(15) Install heater tube support bracket to cylinder
head.
(16) Connect radiator upper and heater hoses to
intake manifold water outlet connections.
(17) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(18) Using new gaskets, install EGR tube and
tighten fasteners to 11 N´m (95 in. lbs.).
(19) Install air inlet tube and housing.
(20) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(21) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(22) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
Fig. 17 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 18 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
Fig. 19 Cylinder Head Tightening Sequence
RSENGINE 2.4L9-27
CYLINDER HEAD (Continued)
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(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 20).
(3) Remove camshaft sprockets.
(4) Remove rear timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(5) Remove camshaft seal using Special Tool
C-4679A (Fig. 21).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
22).
(3) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(4) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.) (Fig. 20).
(5) Install timing belt and front covers (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT AND
SPROCKETS - INSTALLATION) (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
CAMSHAFT(S)
DESCRIPTION
Both camshafts have six bearing journal surfaces
and two cam lobes per cylinder (Fig. 23). Flanges at
the rear journals control camshaft end play. Provision
for a cam position sensor is located on the intake
camshaft on the rear of the cylinder head. A hydro-
dynamic oil seal is used for oil control at the front of
the camshaft.
OPERATION
The camshaft is driven by the crankshaft via drive
sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
duration.
Fig. 20 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 21 Camshaft Oil Seal - Removal With C-4679A
1 - SPECIAL TOOL C-4679
Fig. 22 Camshaft Seal - Installation
1 - SPECIAL TOOL MD-998306
9 - 28 ENGINE 2.4LRS
CAMSHAFT OIL SEAL(S) (Continued)
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STANDARD PROCEDURE - MEASURING
CAMSHAFT END PLAY
(1) Oil camshaft journals and install camshaft
WITHOUTrocker arms. Install rear cam caps and
tighten screws to specified torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
(3) Zero dial indicator (Fig. 24).
(4) Move camshaft as far forward as it will go.
(5) Record reading on dial indicator. For end play
specification, (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
(6) If end play is excessive, check cylinder head
and camshaft for wear; replace as necessary.
REMOVAL
(1) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER - REMOVAL).
(2) Remove camshaft position sensor and camshaft
target magnet (Refer to 8 - ELECTRICAL/IGNITION
CONTROL/CAMSHAFT POSITION SENSOR -
REMOVAL).
(3) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).(4) Remove camshaft sprockets and timing belt
rear cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).
(5) Bearing caps are identified for location.
Remove the outside bearing caps first (Fig. 25).
(6) Loosen the camshaft bearing cap attaching
fasteners in sequence shown (Fig. 26) one camshaft
at a time.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
(7) Identify the camshafts before removing from
the head. The camshafts are not interchangeable.
(8) Remove camshafts from cylinder head.
NOTE: If removing rocker arms, identify for reinstal-
lation in the original position.
CLEANING
Clean camshaft with a suitable solvent.
Fig. 23 Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
Fig. 24 Camshaft End Play - Typical
Fig. 25 Camshaft Bearing Cap Identification
RSENGINE 2.4L9-29
CAMSHAFT(S) (Continued)
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INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 27). If journals are binding, check
the cylinder head for damage. Also check cylinder
head oil holes for clogging.
(2) Check the cam lobe and bearing surfaces for
abnormal wear and damage. Replace camshaft if
defective.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the rocker arms.
(3) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 27) and replace cam-
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wearlimitis 0.254 mm (0.010 in.).
INSTALLATION
CAUTION: Ensure that NONE of the pistons are at
top dead center when installing the camshafts.
(1) Lubricate all camshaft bearing journals, rocker
arms and camshaft lobes.
(2) Install all rocker arms in original positions, if
reused.
(3) Position camshafts on cylinder head bearing
journals. Install right and left camshaft bearing caps
No.2±5andright No. 6. Tighten M6 fasteners to 12
N´m (105 in. lbs.) in sequence shown in (Fig. 28).
(4) Apply MopartGasket Maker to No. 1 and No.
6 bearing caps (Fig. 29). Install bearing caps and
tighten M8 fasteners to 28 N´m (250 in. lbs.).
NOTE: Bearing end caps must be installed before
seals can be installed.
(5) Install camshaft oil seals (Refer to 9 -
ENGINE/CYLINDER HEAD/CAMSHAFT OIL
SEAL(S) - INSTALLATION).
(6) Install camshaft target magnet and camshaft
position sensor.
Fig. 26 Camshaft Bearing Cap - Removal
1 - REMOVE OUTSIDE BEARING CAPS FIRST
Fig. 27 Checking Camshaft(s) for Wear
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
Fig. 28 Camshaft Bearing Cap Tightening Sequence
Fig. 29 Camshaft Bearing Cap Sealing
1 - 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET
MAKER
9 - 30 ENGINE 2.4LRS
CAMSHAFT(S) (Continued)
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