2005 CHRYSLER CARAVAN ors

Also like the cam and crank sensors, a 5 volt ref-
erence is supplied from the PCM and returns a volt-
age signal to the PCM that reflects manifold
pressure. The zero pressure reading is 0.5V and full
scale is 4.5V. For a pressure swing of0Ð15psithe
voltage changes 4.0V. The sensor is supplied a regu-
lated 4.8 to 5.1 volts to operate the sensor. Like the
cam and crank sensors ground is provided through
the sensor return circuit.
The MAP sensor input is the number one contrib-
utor to pulse width. The most important function of
the MAP sensor is to determine barometric pressure.
The PCM needs to know if the vehicle is at sea level
or is it in Denver at 5000 feet above sea level,
because the air density changes with altitude. It will
also help to correct for varying weather conditions. If
a hurricane was coming through the pressure would
be very, very low or there could be a real fair
weather, high pressure area. This is important
because as air pressure changes the barometric pres-
sure changes. Barometric pressure and altitude have
a direct inverse correlation, as altitude goes up baro-
metric goes down. The first thing that happens as
the key is rolled on, before reaching the crank posi-
tion, the PCM powers up, comes around and looks at
the MAP voltage, and based upon the voltage it sees,
it knows the current barometric pressure relative to
altitude. Once the engine starts, the PCM looks at
the voltage again, continuously every 12 milliseconds,
and compares the current voltage to what it was at
key on. The difference between current and what it
was at key on is manifold vacuum.
During key On (engine not running) the sensor
reads (updates) barometric pressure. A normal range
can be obtained by monitoring known good sensor in
you work area.As the altitude increases the air becomes thinner
(less oxygen). If a vehicle is started and driven to a
very different altitude than where it was at key On
the barometric pressure needs to be updated. Any
time the PCM sees Wide Open throttle, based upon
TPS angle and RPM it will update barometric pres-
sure in the MAP memory cell. With periodic updates,
the PCM can make its calculations more effectively.
The PCM uses the MAP sensor to aid in calculat-
ing the following:
²Barometric pressure
²Engine load
²Manifold pressure
²Injector pulse-width
²Spark-advance programs
²Shift-point strategies (F4AC1 transmissions
only, via the PCI bus)
²Idle speed
²Decel fuel shutoff
The PCM recognizes a decrease in manifold pres-
sure by monitoring a decrease in voltage from the
reading stored in the barometric pressure memory
cell. The MAP sensor is a linear sensor; as pressure
changes, voltage changes proportionately. The range
of voltage output from the sensor is usually between
4.6 volts at sea level to as low as 0.3 volts at 26 in. of
Hg. Barometric pressure is the pressure exerted by
the atmosphere upon an object. At sea level on a
standard day, no storm, barometric pressure is 29.92
in Hg. For every 100 feet of altitude barometric pres-
sure drops .10 in. Hg. If a storm goes through it can
either add, high pressure, or decrease, low pressure,
from what should be present for that altitude. You
should make a habit of knowing what the average
pressure and corresponding barometric pressure is
for your area.
REMOVAL
REMOVAL - 2.4L
(1) Disconnect the negative battery cable.
(2) Disconnect electrical connector and vacuum
hose from MAP sensor (Fig. 20).
(3) Remove two screws holding sensor to the
intake manifold.
REMOVAL - 3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Remove vacuum hose and mounting screws
from manifold absolute pressure (MAP) sensor (Fig.
21).
(3) Disconnect electrical connector from sensor.
Remove sensor.
Fig. 21 MAP SENSOR - 3.3/3.8L
RSFUEL INJECTION14-35
MAP SENSOR (Continued)

INSTALLATION
INSTALLATION - 2.4L
(1) Install sensor.
(2) Install two screws and tighten.
(3) Connect the electrical connector and vacuum
hose to the MAP sensor (Fig. 20).
(4) Connect the negative battery cable.
INSTALLATION - 3.3/3.8L
(1) Install sensor (Fig. 21).
(2) Install screws and tighten toPLASTIC MAN-
IFOLD 1.7 N´m (15 in. lbs.) ALUMINUM MANI-
FOLD 3.3 N´m (30 in. lbs.).
(3) Connect the electrical connector to the sensor.
Install vacuum hose.
(4) Connect the negative battery cable.
O2 SENSOR
DESCRIPTION
The upstream oxygen sensor threads into the out-
let flange of the exhaust manifold (Fig. 22) or (Fig.
23).
The downstream heated oxygen sensor threads into
the outlet pipe at the rear of the catalytic convertor
(Fig. 24).
OPERATION
A seperate upstream and downstream grounds are
used on the NGC vehicles (4 Cyl.).
As vehicles accumulate mileage, the catalytic con-
vertor deteriorates. The deterioration results in a
less efficient catalyst. To monitor catalytic convertordeterioration, the fuel injection system uses two
heated oxygen sensors. One sensor upstream of the
catalytic convertor, one downstream of the convertor.
The PCM compares the reading from the sensors to
calculate the catalytic convertor oxygen storage
capacity and converter efficiency. Also, the PCM uses
the upstream heated oxygen sensor input when
adjusting injector pulse width.
When the catalytic converter efficiency drops below
emission standards, the PCM stores a diagnostic
trouble code and illuminates the malfunction indica-
tor lamp (MIL).
The O2 sensors produce a constant 2.5 volts on
NGC vehicles, depending upon the oxygen content of
the exhaust gas. When a large amount of oxygen is
Fig. 22 O2 SENSOR UPSTREAM 1/1 - 2.4L
Fig. 23 O2 SENSOR UPSTREAM 1/1 - 3.3/3.8L
Fig. 24 O2 SENSOR DOWNSTREAM 1/2 - 2.4/3.3/
3.8L
14 - 36 FUEL INJECTIONRS
MAP SENSOR (Continued)

present (caused by a lean air/fuel mixture, can be
caused by misfire and exhaust leaks), the sensors
produces a low voltage. When there is a lesser
amount of oxygen present (caused by a rich air/fuel
mixture, can be caused by internal engine problems)
it produces a higher voltage. By monitoring the oxy-
gen content and converting it to electrical voltage,
the sensors act as a rich-lean switch.
The oxygen sensors are equipped with a heating
element that keeps the sensors at proper operating
temperature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into closed loop operation sooner.
Also, it allows the system to remain in closed loop
operation during periods of extended idle.
In Closed Loop operation the PCM monitors the O2
sensors input (along with other inputs) and adjusts
the injector pulse width accordingly. During Open
Loop operation the PCM ignores the O2 sensor input.
The PCM adjusts injector pulse width based on pre-
programmed (fixed) values and inputs from other
sensors.
NGC Controller - Has a common ground for the
heater in the O2S. 12 volts is supplied to the heater
in the O2S by the NGC controller. Both the upstream
and downstream O2 sensors for NGC are pulse width
modulation (PWM).NOTE: When replacing an O2
Sensor, the PCM RAM memory must be cleared,
either by disconnecting the PCM C-1 connector or
momentarily disconnecting the Battery negative ter-
minal. The NGC learns the characteristics of each O2
heater element and these old values should be
cleared when installing a new O2 sensor. The cus-
tomer may experience driveability issues if this is not
performed.
UPSTREAM OXYGEN SENSOR
The input from the upstream heated oxygen sensor
tells the PCM the oxygen content of the exhaust gas.
Based on this input, the PCM fine tunes the air-fuel
ratio by adjusting injector pulse width.
The sensor input switches from 2.5 to 3.5 volt,
depending upon the oxygen content of the exhaust
gas in the exhaust manifold. When a large amount ofoxygen is present (caused by a lean air-fuel mixture),
the sensor produces voltage as low as 2.5 volt. When
there is a lesser amount of oxygen present (rich air-
fuel mixture) the sensor produces a voltage as high
as 3.5 volt. By monitoring the oxygen content and
converting it to electrical voltage, the sensor acts as
a rich-lean switch.
The heating element in the sensor provides heat to
the sensor ceramic element. Heating the sensor
allows the system to enter into closed loop operation
sooner. Also, it allows the system to remain in closed
loop operation during periods of extended idle.
In Closed Loop, the PCM adjusts injector pulse
width based on the upstream heated oxygen sensor
input along with other inputs. In Open Loop, the
PCM adjusts injector pulse width based on prepro-
grammed (fixed) values and inputs from other sen-
sors.
DOWNSTREAM OXYGEN SENSOR
The downstream heated oxygen sensor input is
used to detect catalytic convertor deterioration. As
the convertor deteriorates, the input from the down-
stream sensor begins to match the upstream sensor
input except for a slight time delay. By comparing
the downstream heated oxygen sensor input to the
input from the upstream sensor, the PCM calculates
catalytic convertor efficiency. Also used to establish
the upstream O2 goal voltage (switching point).
REMOVAL
REMOVAL - UPSTREAM 1/1 - 2.4L
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Disconnect the electrical connector (Fig. 23).
(4) Use a socket such as the Snap-OntYA8875 or
equivalent to remove the sensor
(5) When the sensor is removed, the threads must
be cleaned with an 18 mm X 1.5 + 6E tap. If using
the original sensor, coat the threads with Loctite
771±64 anti-seize compound or equivalent.
RSFUEL INJECTION14-37
O2 SENSOR (Continued)

REMOVAL - UPSTREAM 1/1 - 3.3/3.8L
(1) Remove battery, refer to the Battery section for
more information.
(2) Remove the battery tray, refer to the Battery
section for more information.
(3) Disconnect the speed control vacuum harness
from servo.
(4) Disconnect the electrical connector from servo.
(5) Remove the speed control servo and bracket
and reposition.
(6) Use a socket such as the Snap-OntYA8875 or
equivalent to remove the sensor (Fig. 25).
(7) When the sensor is removed, the threads must
be cleaned with an 18 mm X 1.5 + 6E tap. If using
the original sensor, coat the threads with Loctite
771±64 anti-seize compound or equivalent.
REMOVAL - DOWNSTREAM 1/2 - 2.4/3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Disconnect the electrical connector (Fig. 26).
(4) Use a socket such as the Snap-OntYA8875 or
equivalent to remove the sensor (Fig. 27).
(5) When the sensor is removed, the threads must
be cleaned with an 18 mm X 1.5 + 6E tap. If using
the original sensor, coat the threads with Loctite
771±64 anti-seize compound or equivalent.
INSTALLATION
INSTALLATION - UPSTREAM 1/1 - 2.4L
The engines uses two heated oxygen sensors.
(1) After removing the sensor, the exhaust mani-
fold threads must be cleaned with an 18 mm X 1.5 +
6E tap. If reusing the original sensor, coat the sensor
threads with an anti-seize compound such as Loctite
771- 64 or equivalent. New sensors have compound
on the threads and do not require an additional coat-
ing.
Fig. 25 O2 SENSOR 1/1
Fig. 26 Downstream Oxygen Sensor (1/2)
1 - OXYGEN SENSOR CONNECTOR
2 - CATALYTIC CONVERTER
3 - DOWNSTREAM OXYGEN SENSOR
4 - ENGINE HARNESS CONNECTOR
Fig. 27 DOWNSTREAM 2/1 O2 SENSOR
14 - 38 FUEL INJECTIONRS
O2 SENSOR (Continued)

(2) Install sensor and tighten to 27 N´m (20 ft.
lbs.) (Fig. 23).
(3) Connect the electrical connector for the O2 sen-
sor and install onto bracket.
(4) Lower vehicle.
(5) Connect the negative battery cable.
INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L
The engines uses two heated oxygen sensors.
(1) After removing the sensor, the exhaust mani-
fold threads must be cleaned with an 18 mm X 1.5 +
6E tap. If reusing the original sensor, coat the sensor
threads with an anti-seize compound such as Loctite
771- 64 or equivalent. New sensors have compound
on the threads and do not require an additional coat-
ing.
(2) Install sensor and tighten to 27 N´m (20 ft.
lbs.).
(3) Connect the electrical connector for the O2 sen-
sor and install onto bracket.
(4) Connect the electrical connector for the speed
control servo.
(5) Install the speed control servo and bracket
refer to the Speed Control Servo for more informa-
tion.
(6) Connect the speed control vacuum harness to
servo.
(7) Install the battery tray, refer to the Battery
section for more information.
(8) Install battery, refer to the Battery section for
more information.
INSTALLATION DOWNSTREAM 2/1 -
2.4/3.3/3.8L
The O2S is located on the side of the catalytic con-
verter.
Threads of new oxygen sensors are factory coated
with anti-seize compound to aid in removal.DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) Install sensor and tighten to 27 N´m (20 ft.
lbs.).
(2) Connect the electrical connector.
(3) Lower vehicle.
(4) Install the negative battery cable.
THROTTLE BODY
DESCRIPTION
The throttle body is located on the intake manifold
(Fig. 28) or (Fig. 29). Fuel does not enter the intake
manifold through the throttle body. Fuel is sprayed
into the manifold by the fuel injectors.
OPERATION
Filtered air from the air cleaner enters the intake
manifold through the throttle body. The throttle body
contains an air control passage controlled by an Idle
Air Control (IAC) motor. The air control passage is
used to supply air for idle conditions. A throttle valve
(plate) is used to supply air for above idle conditions.
Certain sensors are attached to the throttle body.
The accelerator pedal cable, speed control cable are
connected to the throttle body cam.
Fig. 28 IAC VALVE 2.4L
1 - Idle Air Control Valve
2 - Throttle Position Sensor
Fig. 29 IAC VALVE LOCATION 3.3/3.8L
1 - Idle Air Control Valve
2 - Throttle Position Sensor
RSFUEL INJECTION14-39
O2 SENSOR (Continued)

A (factory adjusted) set screw is used to mechani-
cally limit the position of the throttle body throttle
plate.Never attempt to adjust the engine idle
speed using this screw.All idle speed functions are
controlled by the PCM.
REMOVAL
(1) Disconnect negative cable from battery cable.
(2) Remove air inlet to throttle body hose clamp.
(3) Remove throttle and the speed control (if
equipped) cables from lever and bracket.
(4) Disconnect electrical connectors from the idle
air control motor and throttle position sensor (TPS)
(Fig. 28) or (Fig. 29).
(5) Remove throttle body to intake manifold
attaching bolts.
(6) Remove throttle body and gasket.
INSTALLATION
(1) Install a new gasket, if required.
(2) Install throttle body.
(3) Tighten throttle body mounting bolts. The 2.4L
to 28.2 N´m (250  50 in. lbs.) torque, The 3.3/3.8L to
11.6 N´m (105  20 in. lbs.) torque.
(4) Connect electrical connectors to the idle air
control motor and throttle position sensor (TPS) (Fig.
28) or (Fig. 29).
(5) Install air inlet to throttle body hose clamp and
tighten.
(6) Connect negative cable to battery cable.
THROTTLE CONTROL CABLE
REMOVAL
(1) Working from the engine compartment, hold
the throttle body throttle lever in the wide open posi-
tion.
(2) Remove the throttle cable from the throttle
body cam.
(3) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft.
(4) Remove retainer clip from throttle cable and
grommet at dash panel.
(5) From the engine compartment, pull the throttle
cable and gromment out of the dash panel.
(6) Remove the throttle cable from throttle bracket
by carefully compressing both retaining ears simulta-
neously then gently pull the throttle cable from
throttle bracket or if it is the slide snap design you
have to slide the locking tab out of the hole and then
slide the cable assembly out of the bracket.
INSTALLATION
(1) From the engine compartment, push the hous-
ing end fitting and grommet into the dash panel.In-
stall gromment into the dash panel.
(2) Install the cable housing (throttle body end)
into the cable mounting bracket on the engine.
(3) From inside the vehicle, hold up the pedal and
install throttle cable and cable retainer in the upper
end of the pedal shaft.
(4) At the dash panel, install the cable retainer
clip between the end of the throttle cable fitting and
grommet
(5) From the engine compartment, rotate the
throttle lever wide open and install the throttle
cable.
THROTTLE POSITION SENSOR
DESCRIPTION
The throttle position sensor mounts to the side of
the throttle body (Fig. 30) or (Fig. 31).The sensor
connects to the throttle blade shaft. The TPS is a
variable resistor that provides the Powertrain Con-
trol Module (PCM) with an input signal (voltage).
Fig. 30 Throttle Position SensorÐ2.4L Engine
1 - Idle Air Control Valve
2 - Throttle Position Sensor
14 - 40 FUEL INJECTIONRS
THROTTLE BODY (Continued)

OPERATION
The signal represents throttle blade position. As
the position of the throttle blade changes, the resis-
tance of the TPS changes.
The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade
position. The TPS output voltage to the PCM varies
from approximately 0.6 volt at minimum throttle
opening (idle) to a maximum of 4.5 volts at wide open
throttle.Along with inputs from other sensors, the PCM
uses the TPS input to determine current engine oper-
ating conditions. The PCM also adjusts fuel injector
pulse width and ignition timing based on these
inputs.
REMOVAL - 3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Remove the electrical connector from the Inlet
Air Temperature sensor.
(3) Remove the air cleaner box lid. Remove hose
from throttle body.
(4) Disconnect the electrical connector at TPS.
(5) Disconnect the electrical connector at IAC.
(6) Remove the throttle and speed control cables
from throttle body.
(7) Remove 3 mounting bolts from throttle body.
(8) Remove throttle body.
(9) Disconnect the purge vacuum line from the
throttle body.
(10) Remove TPS from throttle body.
INSTALLATION - 3.3/3.8L
(1) Install TPS to throttle body.
(2) Disconnect the purge vacuum line from the
throttle body.
(3) Install throttle body.
(4) Install 3 mounting bolts from throttle body.
Tighten bolts.
(5) Install the throttle and speed control cables to
throttle body.
(6) Connect the electrical connector at TPS.
(7) Connect the electrical connector at IAC.
(8) Install the air cleaner box lid. Install hose to
throttle body.
(9) Install the electrical connector to the Inlet Air
Temperature sensor.
(10) Connect the negative battery cable.
Fig. 31 Throttle Position SensorÐ3.3/3.8L Engine
1 - Idle Air Control Valve
2 - Throttle Position Sensor
RSFUEL INJECTION14-41
THROTTLE POSITION SENSOR (Continued)

WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIR BAG COMPONENTS, HAVE SPECIAL
COATINGS AND ARE SPECIFICALLY DESIGNED
FOR THE AIR BAG SYSTEM. THEY MUST NEVER
BE REPLACED WITH ANY SUBSTITUTES. ANYTIME
A NEW FASTENER IS NEEDED, REPLACE WITH
THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR FASTENERS LISTED IN
THE PARTS BOOKS.
WARNING: SAFETY GOGGLES SHOULD BE WORN
AT ALL TIMES WHEN WORKING ON STEERING
COLUMNS.
CAUTION: Disconnect negative (ground) cable from
the battery before servicing any column compo-
nent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
DIAGNOSIS AND TESTING - STEERING
COLUMN
For diagnosis of conditions relating to the steering
column, (Refer to 19 - STEERING - DIAGNOSIS
AND TESTING).
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - REMOVAL).
(1) Make sure the front wheels of the vehicle are
in the STRAIGHT AHEAD position before beginning
the column removal procedure.
(2) Disconnect and isolate the negative (ground)
cable from the battery. Wait at least two minutes for
the airbag system reserve capacitor to discharge
before beginning any steering column, instrument
panel, or airbag system/component service.WARNING: WHEN AN UNDEPLOYED AIRBAG IS TO
BE REMOVED FROM THE VEHICLE, FIRST DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE. ALLOW THE AIRBAG SYSTEM
RESERVE CAPACITOR TO DISCHARGE FOR TWO
MINUTES BEFORE BEGINNING ANY AIRBAG SYS-
TEM OR COMPONENT SERVICE. PERSONAL
INJURY MAY RESULT IF THIS PROCEDURE IS NOT
FOLLOWED.
(3) Remove the driver airbag mounting screws
(Fig. 2).
(4) Lift the airbag from its mount and disconnect
two airbag squib, speed control and horn connectors
(Fig. 3). Remove driver airbag. Properly store the
driver airbag out of the way. (Refer to 8 - ELECTRI-
CAL/RESTRAINTS - WARNING)
(5) Remove the steering wheel retaining bolt (Fig.
4).
(6) Remove damper (Fig. 4).
(7) If equipped, disconnect the remote audio con-
trol switch wiring from the clockspring (Fig. 4).
CAUTION: Do not bump or hammer on steering col-
umn or steering column shaft when removing steer-
ing wheel from steering column shaft.
CAUTION: When installing steering wheel puller
bolts in steering wheel, do not thread bolt into
steering wheel more than a half inch. If the bolts
are threaded into the steering wheel more than a
half inch they will contact and damage the clock-
spring.
Fig. 2 Driver Airbag Mounting
1 - DRIVER AIRBAG
2 - MOUNTING SCREWS
RSCOLUMN19-11
COLUMN (Continued)