2005 CHRYSLER VOYAGER power modul

opposite preset limit or switch point. The process
then repeats itself in the opposite direction.
Short term fuel correction will keep increasing or
decreasing injector pulse-width based upon the
upstream O2 Sensor input. The maximum range of
authority for short term memory is 25% (+/-) of base
pulse-width. Short term is violated and is lost when
ignition is turned OFF.
Long Term
The second fuel correction program is the long
term adaptive memory. In order to maintain correct
emission throughout all operating ranges of the
engine, a cell structure based on engine rpm and load
(MAP) is used.
Ther number of cells varies upon the driving con-
ditions. Two cells are used only during idle, based
upon TPS and Park/Neutral switch inputs. There
may be two other cells used for deceleration, based
on TPS, engine rpm, and vehicle speed. The other
twelve cells represent a manifold pressure and an
rpm range. Six of the cells are high rpm and the
other six are low rpm. Each of these cells has a spe-
cific MAP voltage range Typical Adaptive Memory
Fuel Cells.As the engine enters one of these cells the PCM
looks at the amount of short term correction being
used. Because the goal is to keep short term at 0 (O2
Sensor switching at 0.5 volt), long term will update
in the same direction as short term correction was
moving to bring the short term back to 0. Once short
term is back at 0, this long term correction factor is
stored in memory.
The values stored in long term adaptive memory
are used for all operating conditions, including open
loop and cold starting. However, the updating of the
long term memory occurs after the engine has
exceeded approximately 170É-190É F, with fuel control
in closed loop and two minutes of engine run time.
This is done to prevent any transitional temperature
or start-up compensations from corrupting long term
fuel correction.
Long term adaptive memory can change the pulse-
width by as much as 25%, which means it can correct
for all of short term. It is possible to have a problem
that would drive long term to 25% and short term to
another 25% for a total change of 50% away from
base pulse-width calculation.
TYPICAL ADAPTIVE MEMORY FUEL CELLS
Open
ThrottleOpen
ThrottleOpen
ThrottleOpen
ThrottleOpen
ThrottleOpen
Throttle Idle Decel
Vacuum 20 17 13 9 5 0
Above 1,984
rpm1 3 5 7 9 11 13 Drive 15
Below 1,984
rpm02 4 6 8 1012
Neutral14
MAP volt =0 1.4 2.0 2.6 3.3 3.9
Fuel Correction Diagnostics
There are two fuel correction diagnostic routines:
²Fuel System Rich
²Fuel System Lean
A DTC is set and the MIL is illuminated if the
PCM detects either of these conditions. This is deter-
mined based on total fuel correction, short term
times long term.
PROGRAMMABLE COMMUNICATIONS
INTERFACE (PCI) BUS
DESCRIPTION
The Programmable Communication Interface Mul-
tiplex system (PCI Bus) consist of a single wire. The
Body Control Module (BCM) acts as a splice to con-nect each module and the Data Link Connector
(DLC) together. Each module is wired in parallel to
the data bus through its PCI chip set and uses its
ground as the bus reference. The wiring is a mini-
mum 20 gage wire.
OPERATION
Various modules exchange information through a
communications port called the PCI Bus. The Power-
train Control Module (PCM) transmits the Malfunc-
tion Indicator Lamp (Check Engine) On/Off signal
and engine RPM on the PCI Bus. The PCM receives
the Air Conditioning select input, transaxle gear
position inputs over the PCI Bus. The PCM also
receives the air conditioning evaporator temperature
signal from the PCI Bus.
RSFUEL INJECTION14-25
FUEL INJECTION (Continued)

The following components access or send informa-
tion on the PCI Bus.
²Instrument Panel
²Body Control Module
²Air Bag System Diagnostic Module
²Full ATC Display Head (if equipped)
²ABS Module
²Transmission Control Module
²Powertrain Control Module
²Travel Module
²SKIMSYSTEM DIAGNOSIS
OPERATION
The PCM can test many of its own input and out-
put circuits. If the PCM senses a fault in a major
system, the PCM stores a Diagnostic Trouble Code
(DTC) in memory.
For DTC information see On-Board Diagnostics
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/POWERTRAIN CONTROL MOD-
ULE - DESCRIPTION) .
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
MAP SENSOR PLASTIC
MANIFOLD1.7 15
MAP SENSOR
ALUMINUM MANIFOLD3.3 30
POWER STEERING
RESERVOIR PLASTIC
MANIFOLD5.7 50
POWER STEERING
RESERVOIR ALUMINUM
MANIFOLD11.9 105
THROTTLE CABLE
BRACKET PLASTIC
MANIFOLD5.7 50
THROTTLE CABLE
BRACKET ALUMINUM
MANIFOLD11.9 105
EGR TUBE PLASTIC
MANIFOLD5.7 50
EGR TUBE ALUMINUM
MANIFOLD11.9 105
THROTTLE BODY BOLTS
2.4L28 20.65 250  50
THROTTLE BODY BOLTS
3.3/3.8L11.8 8.7 105  20
O2 Sensors 27 20
The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and
installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600
rpms) to avoid melting the parent material. There are service repair screws avialable for repair. They require a
higher torque than the original screws..
14 - 26 FUEL INJECTIONRS
FUEL INJECTION (Continued)

CRANKSHAFT POSITION
SENSOR
DESCRIPTION
The 2.4L crankshaft sensor is located on the rear
of the engine near the accessory drive belt (Fig. 4).
The 3.3/3.8L crankshaft sensor is located on the rear
of the transmission housing, above the differential
housing (Fig. 5). The bottom of the sensor is posi-
tioned next to the drive plate.
OPERATION
The crankshaft position sensor detects slots cut
into the transmission driveplate extension (Fig. 6).
There are 3 sets of slots. Each set contains 4 slots,
for a total of 12 slots (Fig. 7). Basic timing is set by
the position of the last slot in each group. Once the
Powertrain Control Module (PCM) senses the last
slot, it determines crankshaft position (which piston
will next be at TDC) from the camshaft position sen-
sor input. The 4 pulses generated by the crankshaft
position sensor represent the 69É, 49É, 29É, and 9É
BTDC marks. It may take the PCM one engine rev-
olution to determine crankshaft position.
Fig. 4 CRANKSHAFT SENSOR 2.4L
Fig. 5 CRANKSHAFT SENSOR 3.3/3.8L
Fig. 6 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
Fig. 7 Timing Slots
1 - TORQUE CONVERTER DRIVE PLATE
2 - SLOTS
RSFUEL INJECTION14-29

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)

(12) Remove the fasteners, then the accessory
drive splash shield.
(13) Remove the adjuster nut attaching rear of
power steering pump to the cast mounting bracket.
(Fig. 7)
(14) Remove the front adjuster nut and the lower
pivot bolt (Fig. 8) attaching power steering pump
bracket to cast bracket.
(15) Remove the drive belt from the power steering
pump pulley.
(16) Remove the power steering pump and the
front bracket from the cast bracket on the engine as
an assembly through the exhaust tunnel.(17) Remove the 3 bolts attaching the front
bracket to the power steering pump and separate the
power steering pump from the front bracket.
(18) If the power steering pump pulley needs to be
transferred, (Refer to 19 - STEERING/PUMP - DIS-
ASSEMBLY).
REMOVAL - PUMP (3.3L/3.8L ENGINE)
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove the wiper module (unit)(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL).
(3) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove the drive belt splash shield.
(5) Remove the pressure hose routing bracket bolt
(Fig. 9).
(6) lower the vehicle.
(7) Remove cap from power steering fluid reser-
voir.
(8) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(9) Disconnect the pressure hose from the pump
(Fig. 10).
(10) Disconnect the fluid supply hose from the
pump (Fig. 10).
Fig. 7 Power Steering Pump Attaching Nut
1 - POWER STEERING PUMP MOUNTING BRACKET
2 - FRONT SUSPENSION CRADLE
3 - POWER STEERING PUMP
4 - ADJUSTER NUT
Fig. 8 Pump Front Mounting
1 - ADJUSTER NUT
2 - PIVOT BOLT
3 - PUMP
Fig. 9 Pressure Hose Routing Clamp
1 - PRESSURE HOSE TUBE
2 - STEERING GEAR
3 - CRADLE CROSSMEMBER
4 - DRIVESHAFT
5 - ROUTING CLAMP BRACKET
19 - 40 PUMPRS
PUMP (Continued)

INSTALLATION
INSTALLATION - PUMP (2.4L ENGINE)
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
exhaust tunnel of the vehicle.
(2) Install the power steering pump on its cast
mounting bracket (Fig. 7), then install the nut and
bolt attaching the front bracket to the cast bracket
(Fig. 8).Do not fully tighten at this time..
(3) Install the rear nut (Fig. 7).
(4) Install the power steering pump drive belt on
pulley and adjust (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - INSTALLATION).
(5) Tighten the two adjustment slot bolts and the
one pivot bolt to 54 N´m (40 ft. lbs.) torque.
(6) Install the accessory drive splash shield.
NOTE: Before installing power steering fluid pres-
sure hose on power steering pump, inspect the
O-ring on the pressure hose for damage and
replace if necessary.
(7) Install the power steering fluid pressure line
onto the output fitting of the power steering pump
(Fig. 6). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N´m (275 in. lbs.).
(8) Install the power steering fluid low pressure
return hose on the power steering pump low pressure
fitting (Fig. 6).Be sure hose clamps are properly
reinstalled.
(9) Install the power steering fluid supply hose on
the power steering pump fluid fitting.Be sure hose
is clear of accessory drive belts all hose clamps
are properly reinstalled.
CAUTION: Heat sleeve must cover entire rubber
portion of return hose to ensure desired thermal
protection from exhaust.
(10) Properly position the protective heat sleeve
over the power steering return hose. Securely tie
strap the heat sleeve to the power steering hose to
keep in it's proper position.
(11)
Install the exhaust system (Fig. 4). Install all
exhaust system isolators/hangers on the exhaust sys-
tem brackets, then the four bolts and flag nuts (Fig. 3).
(12) Connect the oxygen sensor wiring harness to
the vehicle wiring harness.
(13) Lower vehicle.
(14) Connect the negative battery cable on the
negative battery post.
(15) Perform the POWER STEERING PUMP INI-
TIAL OPERATION procedure to properly fill and
bleed the power steering system. (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE)
(16) Inspect for leaks.
INSTALLATION - PUMP (3.3L/3.8L ENGINE)
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the
engine compartment of the vehicle.
(2) Install the power steering pump on its mount-
ing bracket.
(3) Install the 3 front power steering pump mount-
ing bolts (Fig. 11). Tighten the 3 front power steering
pump mounting bolts to a torque of 54 N´m (40 ft.
lbs.).
NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(4) Install the power steering fluid pressure line
into the pressure output fitting of the power steering
pump (Fig. 10).Do not fully tighten tube nut at
this time.
(5) Install the power steering fluid supply hose on
the power steering pump supply fitting (Fig. 10).Be
sure hose clamp is properly installed.
(6) Raise the vehicle.
(7) Install the routing clip on the engine for the
pressure hose (Fig. 9) and tighten fastener.
(8) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(9) Install the drive belt splash shield.
(10) Lower the vehicle.
(11) Tighten the pressure line to pump pressure
fitting tube nut to a torque of 31 N´m (275 in. lbs.).
(12) Install the wiper module (unit)(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(13) Connect the negative battery cable on the
negative battery post.
(14) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(15) Inspect for leaks.
INSTALLATION - PUMP (DIESEL)
(1) Install the power steering pump on its cast
mounting bracket.
(2) Install the three front power steering pump
mounting bolts. Tighten the mounting bolts to a
torque of 54 N´m (40 ft. lbs.).
(3) Install the rear mounting bolt fastening the
stamped bracket to the cast bracket (Fig. 13).
Tighten the mounting bolt to a torque of 54 N´m (40
ft. lbs.).
RSPUMP19-43
PUMP (Continued)

SPEED SENSOR - INPUT
DESCRIPTION........................120
OPERATION..........................120
REMOVAL............................121
INSTALLATION........................121
SPEED SENSOR - OUTPUT
DESCRIPTION........................122
OPERATION..........................122
REMOVAL............................123
INSTALLATION........................123
TORQUE CONVERTER
DESCRIPTION........................124
OPERATION..........................128
REMOVAL............................129
INSTALLATION........................129TRANSMISSION CONTROL RELAY
DESCRIPTION........................130
OPERATION..........................130
TRANSMISSION RANGE SENSOR
DESCRIPTION........................130
OPERATION..........................131
REMOVAL............................131
INSTALLATION........................131
VALVE BODY
DESCRIPTION........................132
OPERATION..........................132
REMOVAL............................133
DISASSEMBLY........................135
ASSEMBLY...........................139
INSTALLATION........................144
40TE AUTOMATIC
TRANSAXLE
DESCRIPTION
The 40TE (Fig. 1) is a four-speed transaxle that is
a conventional hydraulic/mechanical assembly with
an integral differential, and is controlled with adap-
tive electronic controls and monitors. The hydraulic
system of the transaxle consists of the transaxle
fluid, fluid passages, hydraulic valves, and various
line pressure control components. An input clutch
assembly which houses the underdrive, overdrive,
and reverse clutches is used. It also utilizes separate
holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:
²Three multiple disc input clutches
²Two multiple disc holding clutches
²Four hydraulic accumulators
²Two planetary gear sets
²Hydraulic oil pump
²Valve body²Solenoid/Pressure switch assembly
²Integral differential assembly
Control of the transaxle is accomplished by fully
adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
feedback information provided to the Powertrain
Control Module (PCM) or Transmission Control Mod-
ule (TCM).
The PCM/TCM is the heart of the electronic control
system and relies on information from various direct
and indirect inputs (sensors, switches, etc.) to deter-
mine driver demand and vehicle operating condi-
tions. With this information, the PCM/TCM can
calculate and perform timely and quality shifts
through various output or control devices (solenoid
pack, transmission control relay, etc.).
The PCM/TCM also performs certain self-diagnos-
tic functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
21 - 2 40TE AUTOMATIC TRANSAXLERS