2005 CHRYSLER CARAVAN sensor

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..........................4
OPERATION............................4
REMOVAL
REMOVAL - 2.4L.......................5
REMOVAL - 3.3/3.8L....................5
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.............................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 ignition system used on these engines is
referred to as the Direct Ignition System (DIS). The
system's three main components are the coils, crank-
shaft position sensor, and camshaft position sensor. If
equipped with the coil on plug ignition system it uti-
lizes 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

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)

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 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 certain drivers on NGC vehicles.
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).
The ASD relay 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
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 pre-
determined value (typically about 50 rpm). 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. On NGC vehi-
cles it checks the O2 heater upon vehicle start. The
PCM still operates internally to perform several
checks, including monitoring the O2 sensor heaters.
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)

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.
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.
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
8I - 4 IGNITION CONTROLRS

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).
(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.
Fig. 3 EGR/CAM SENSOR 2.4L
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
RSIGNITION CONTROL8I-5
CAMSHAFT POSITION SENSOR (Continued)

(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).
(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. 7 Target Magnet Installation
1 - LOCATING DOWELS
2 - LOCATING HOLES (2)
Fig. 8 Camshaft Position Sensor and Spacer
1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
8I - 6 IGNITION CONTROLRS
CAMSHAFT POSITION SENSOR (Continued)

INSTALLATION - 3.3/3.8L
(1) Install coil over studs on bracket.
(2) Install 2 nuts to the ignition coil studs. Tighten
nuts and bolts.
(3) Connect the electrical connector to the ignition
coil.
(4) Install the ignition cables to the ignition coil.
(5) Reposition the Power steering reservoir. Slide
bracket over the mounting stud (Fig. 11).
(6) Install 2 bolts to the Power steering reservoir
to intake manifold.
(7) Tighten the lower nut to stud on ignition coil
bracket.
(8) Install the throttle and speed control cables to
clip.
(9) Connect the negative battery cable.
KNOCK SENSOR
DESCRIPTION
The knock sensor threads into the cylinder block.
The knock sensor is designed to detect engine vibra-
tion that is caused by detonation.
OPERATION
When the knock sensor detects a knock in one of
the cylinders, it sends an input signal to the PCM. In
response, the PCM retards ignition timing for all cyl-
inders by a scheduled amount.
Knock sensors contain a piezoelectric material
which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal's vibration increases, the
knock sensor output voltage also increases.
The voltage signal produced by the knock sensor
increases with the amplitude of vibration. The PCM
receives as an input the knock sensor voltage signal.
If the signal rises above a predetermined level, the
PCM will store that value in memory and retard
ignition timing to reduce engine knock. If the knock
sensor voltage exceeds a preset value, the PCM
retards ignition timing for all cylinders. It is not a
selective cylinder retard.
The PCM ignores knock sensor input during engine
idle conditions. Once the engine speed exceeds a
specified value, knock retard is allowed.
Knock retard uses its own short term and long
term memory program.
Long term memory stores previous detonation
information in its battery-backed RAM. The maxi-
mum authority that long term memory has over tim-
ing retard can be calibrated.
Short term memory is allowed to retard timing up
to a preset amount under all operating conditions (as
long as rpm is above the minimum rpm) except WOT.The PCM, using short term memory, can respond
quickly to retard timing when engine knock is
detected. Short term memory is lost any time the
ignition key is turned off.
NOTE: Over or under tightening affects knock sen-
sor performance, possibly causing improper spark
control.
REMOVAL
REMOVAL - 2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 12).
(1) Disconnect electrical connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensors.
REMOVAL - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) On All Wheel Drive vehicles remove the PTU
(Power Transfer Unit), refer to the Transmission sec-
tion for more information.
(4) Disconnect electrical connector from knock sen-
sor.
(5) Use a crow foot socket to remove the knock
sensor.
INSTALLATION
INSTALLATION - 2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 12).
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
INSTALLATION - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
(3) On All Wheel Drive vehicles install the PTU
(Power Transfer Unit) for the rear wheels, refer to
the Transmission section for more information.
8I - 8 IGNITION CONTROLRS
IGNITION COIL (Continued)

(4) Lower vehicle.
(5) Connect the negative cable.
SPARK PLUG
DESCRIPTION
DESCRIPTION - STANDARD 4 CYLINDER
All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Refer to the Specifications section for gap and type
of spark plug.
DESCRIPTION - PLATINUM PLUGS
The V6 engines use platinum resistor spark plugs.
They have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester. For
spark plug identification and specifications, Refer to
the Specifications section.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.When the spark plugs use a single or double plat-
inum tips and they have a recommended service life
of 100,000 miles for normal driving conditions per
schedule A in this manual. The spark plugs have a
recommended service life of 75,000 miles for severe
driving conditions per schedule B in this manual. A
thin platinum pad is welded to both or just the cen-
ter electrode end(s) as shown in (Fig. 13). Extreme
care must be used to prevent spark plug cross
threading, mis-gapping (Fig. 14) and ceramic insula-
tor damage during plug removal and installation.
CAUTION: Cleaning of the platinum plug may dam-
age the platinum tip.
Fig. 12 Knock Sensor
1 - GENERATOR
2 - INTAKE MANIFOLD
3 - KNOCK SENSOR
4-STARTER
Fig. 13 Platinum Pads
1 - APPLY ANTI-SEIZE COMPOUND HERE ONLY
2 - PLATINUM SPARK SURFACE
Fig. 14 Setting Spark Plug Electrode Gap
1 - TAPER GAUGE
RSIGNITION CONTROL8I-9
KNOCK SENSOR (Continued)