Ignition switch CHRYSLER VOYAGER 2002 Repair Manual

OPERATION
A LED indicator will illuminate when the switch is
activated. The switch energizes the HVAC control
assembly when it requests the Front Control Module
(FCM) to activate the rear window defogger relay.
The relay controls the current to flow to the grids of
the rear window defogger and the heated power side
view mirrors. The defogger relay will be on for
approximately 10 minutes or until the control switch
or ignition is turned off.
HEATED MIRROR GRID
STANDARD PROCEDURE - HEATED MIRROR
Replacement of the mirror is necessary if the grid
is damaged and diagnostics have been performed
(Refer to 23 - BODY/EXTERIOR/SIDE VIEW MIR-
ROR - REMOVAL).
RELAY
DESCRIPTION
There is no heated mirror relay it is integrated
into the (E.B.L) relay that is located in the IPM in
the engine compartment.
8G - 6 HEATED MIRRORSRS
MIRROR SWITCH (Continued)
ProCarManuals.com

²Heated Seat Switch- Two heated seat
switches are used per vehicle, one for the driver and
one for the passenger side front seats. The switches
are mounted to in the instrument panel center stack.
Refer to the description of the heated seat switch
later in this section for additional information.
Hard wired circuitry connects the heated seat sys-
tem components to each other through the electrical
system of the vehicle. These hard wired circuits are
integral to several wire harnesses, which are routed
throughout the vehicle and retained by many differ-
ent methods. These circuits may be connected to each
other, to the vehicle electrical system and to the
heated seat system components through the use of a
combination of soldered splices and splice block con-
nectors. Refer to Wiring for complete system wiring
schematics. The wiring information also includes the
proper wire and connector repair procedures, further
details on wire harness routing and retention, as well
as pin-out and location views for the various wire
harness connectors, splices and grounds.
OPERATION
The heated seat system components operate on
battery current received through a fuse in the Inte-
grated Power Module (IPM) on a fused ignition
switch output (run-acc) circuit so that the system willonly operate when the ignition switch is in the On or
Accessory positions. The heated seat system will be
turned Off automatically whenever the ignition
switch is turned to any position except On or Acces-
sory. Also, the heated seat system will not operate
when the surface temperature of the seat cushion
cover at either heated seat sensor is above the
designed temperature set points of the system. The
heated seat system has a self-diagnostic capability.
When certain failures are detected within the heated
seat system, the system will provide a visual indica-
tion of the failure by flashing the Light Emitting
Diode (LED) indicator lamps located in the heated
seat switches. See the owner's manual in the vehicle
glove box for more information on the features, use
and operation of the heated seat system.
DIAGNOSIS AND TESTING - HEATED SEAT
SYSTEM
Refer toWiring Diagramsfor complete wiring
schematics. The wiring information also includes the
proper wire and connector repair procedures, further
details on wire harness routing and retention, as well
as pin-out and location views for the various wire
harness connectors, splices and grounds.
HEATED SEAT SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO HEATED SEAT SWITCH
ILLUMINATION WITH
IGNITION ON (SYSTEM ON)1. Faulty fuse 1. Check heated seat fuse in Integrated Power
Module. Replace fuse, repair short if required.
2. Faulty components 2. Refer to individual Heated Seat System
components for the proper diagnosis and testing
procedures.
3. Ground faulty 3. Check for ground at heated seat switch and
module. Repair, if required.
4. Wiring faulty 4. Check fused ignition switch output (run-acc)
circuits at switch and module. Repair, if required.
8G - 8 HEATED SEAT SYSTEMRS
HEATED SEAT SYSTEM (Continued)
ProCarManuals.com

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%.
(4) Reconnect the instrument panel switch bank
and test the heated seat system for proper operation.If the system is still inoperative proceed with check-
ing remaining components.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE RESTRAINTS SECTION OF
THIS MANUAL BEFORE ATTEMPTING ANY STEER-
ING 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.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel center bezel.
Refer toInstrument Panel Center Bezelin the
Body section for the procedure.
(3) Remove the three screws (Fig. 4) that secure
the heated seat switch to the back of the instrument
panel center bezel.
(4) Remove the heated seat switch from the back
of the instrument panel center bezel.
INSTALLATION
(1) Position the heated seat switch onto the back
of the instrument panel center bezel.
Fig. 3 Instrument Panel Switch Bank Connector
Fig. 4 SWITCH RETAINING SCREWS
1 - HEATED SEAT SWITCH ASSEMBLY
2 - RETAINING SCREWS
8G - 10 HEATED SEAT SYSTEMRS
DRIVER HEATED SEAT SWITCH (Continued)
ProCarManuals.com

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%.(4) Reconnect the instrument panel switch bank
and test the heated seat system for proper operation.
If the system is still inoperative proceed with check-
ing remaining components.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE RESTRAINTS SECTION OF
THIS MANUAL BEFORE ATTEMPTING ANY STEER-
ING 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.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel center bezel.
Refer toInstrument Panel Center Bezelin the
Body section for the procedure.
(3) Remove the three screws (Fig. 8) that secure
the heated seat switch to the back of the instrument
panel center bezel.
(4) Remove the heated seat switch from the back
of the instrument panel center bezel.
Fig. 7 Instrument Panel Switch Bank Connector
Fig. 8 SWITCH RETAINING SCREWS
1 - HEATED SEAT SWITCH ASSEMBLY
2 - RETAINING SCREWS
8G - 14 HEATED SEAT SYSTEMRS
PASSENGER HEATED SEAT SWITCH (Continued)
ProCarManuals.com

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 cyl-
inder. TDC occurs after the camshaft pulse (or
pulses) and after the 4 crankshaft pulses associatedwith 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).
(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. 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
CAMSHAFT POSITION SENSOR (Continued)
ProCarManuals.com

IGNITION CONTROL
TABLE OF CONTENTS
page page
GLOW PLUG
DESCRIPTION..........................1
OPERATION............................1
GLOW PLUG RELAY
DESCRIPTION..........................1
OPERATION............................1CAMSHAFT POSITION SENSOR
DESCRIPTION..........................2
OPERATION............................2
REMOVAL.............................2
INSTALLATION..........................2
GLOW PLUG
DESCRIPTION
Glow plugs are used to help start a cold or cool
engine (Fig. 1). The glow plugs will heat up and glow
to heat the combustion chamber of each cylinder. An
individual glow plug is used for each cylinder. Each
glow plug is threaded into the left side of the cylinder
head below the cylinder head cover/intake manifold.
OPERATION
Each glow plug will momentarily draw approxi-
mately 25 amps of electrical current during the ini-
tial key ªONº cycle. This is on a cold or cool engine.
After heating the current draw will drop to approxi-
mately 9±12 amps per plug.
Total momentary cuurent draw for all four glow
plugs is approximately 100 amps on a cold engine
dropping to a total of approximately 40 amps after
the plugs are heated.
Electrical operation of the glow plugs is controlled
by two glow plug relays. Each glow plug relay con-
trols two glow plugs. Refer to glow plug relays for
more information.
GLOW PLUG RELAY
DESCRIPTION
There are two glow plug relays. These relays are
located in the Power Distribution Center (PDC) in
the engine compartment (Fig. 2).
OPERATION
When the ignition (key) switch is place in the ON
position, a signal is sent to the ECM relating current
engine coolant temperature. This signal is sent from
the engine coolant temperature sensor.
After receiving this signal, the ECM will determine
if, when and for how long of a period the glow plug
relays should be activated. This is done before, dur-
ing and after the engine is started. Whenever the
glow plug relays are activated, it will control the 12
volt 100 amp circuit for the operation of the four
glow plugs. Each relay control two glow plugs.
Fig. 1 GLOW PLUG
Fig. 2 RELAY LOCATIONS
1 - GLOW PLUG RELAY
2 - RADIATOR SUPPORT
3 - CHARGE AIR COOLER OUTLET HOSE
4 - COOLING FAN RELAY
5 - UPPER RADIATOR HOSE
6 - EGR SOLENOID
RGIGNITION CONTROL8Ia-1
ProCarManuals.com

The Glow Plug lamp is tied to this circuit. Lamp
operation is also controlled by the ECM.
With a cold engine, the glow plug relays and glow
plugs may be activated for a maximum time of 200
seconds. Refer to the following Glow Plug Control
chart for a temperature/time comparison of the glow
plug relay operation.
In this chart, Pre-Heat and Post-Heat times are
mentioned. Pre-Heat is the amount of time the glow
plug relay control circuit is activated when the igni-
tion (key) is switched ON, without the engine run-
ning. Post-Heat is the amount of time the glow plug
relay control circuit is activated after the engine is
operated. The Glow Plug lamp will not be activated
during the post-heat cycle.
Engine
Coolant
Temperature
9Key ON9Wait-To
Start Lamp
9ON9
(Seconds)Pre-Heat
Cycle
(Glow
Plugs On
Seconds)Post-Heat
Cycle
(Seconds)
-30C 20 SEC. 35 SEC. 200 SEC.
-10C 8 SEC. 23 SEC. 180 SEC.
+10C 6 SEC. 21 SEC. 160 SEC.
+30C 5 SEC. 20 SEC. 140 SEC.
+40C 4 SEC. 19 SEC. 70 SEC.
+70C 1 SEC. 16 SEC. 20 SEC.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
The camshaft position (CMP) sensor is mounted in
the top of cylinder head cover/intake manifold at the
rear of the engine. The CMP sensor is a hall effect
device (Fig. 3).
OPERATION
The CMP sensor is a hall effect switch. A tooth
made of a ferromagnetic material is attached to the
camshaft. When this tooth passes the CMP sensor an
lectronic signal is created. This signal is then sent to
the engine control module (ECM). This signal is used
by the ECM to determine which cylinder has just
entered its compression phase.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Disconnect camshaft position sensor electrical
connector (Fig. 4).
(4) Remove sensor retaining bolt and remove sen-
sor from cylinder head cover.
INSTALLATION
(1) Lubricate O-ring and install sensor in cylinder
head cover. Torque retaining bolt to 5.4 N´m.
(2) Connect camshaft position sensor electrical
connector.
(3) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
(4) Connect negative battery cable.
Fig. 3 CAMSHAFT POSITION SENSOR
Fig. 4 CAMSHAFT POSITION SENSOR LOCATION
1 - CAMSHAFT POSITION SENSOR
2 - CAMSHAFT POSITION SENSOR ELCTRICAL SENSOR
3 - FUEL INJECTOR
4 - CYLINDER HEAD COVER
5 - OIL SEPARATOR
8Ia - 2 IGNITION CONTROLRG
GLOW PLUG RELAY (Continued)
ProCarManuals.com

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-
DIAGNOSTICS
The instrument clusters are equipped with a self
diagnostic test feature to help identify electronic
problems. Prior to any test, perform the Self-Diag-
nostic Test. The self diagnostic system displays
instrument cluster stored fault codes in the odometer
display, sweeps the gauges to the calibration points,
and bulb checks the warning indicators. When the
key is in the ON position with the engine not run-
ning, the MIL will remain illuminated for regulatory
purposes.
To activate the Self-Diagnostic program:
(1) With the ignition switch in the OFF position,
depress the TRIP ODOMETER RESET button.
(2) Continue to hold the TRIP ODOMETER
RESET button untilSofand a number (software ver-
sion number (i.e.Sof 3.2) appears in the odometer
window then release the button. If a fault code is
present, the cluster will display it in the odometer
display. When all fault codes have been displayed,
the cluster will displayªendºin the odometer dis-
play. Refer to the INSTRUMENT CLUSTER DTC'S
table to determine what each trouble code means.
INSTRUMENT CLUSTER DTC'S
DTC DESCRIPTION
100.0 LOOP-BACK FAILURE
100.1 ABS COMMUNICATION FAULT
100.2 BCM COMMUNICATION FAULT
100.3 EATX COMMUNICATION FAULT
100.4 FCM COMMUNICATION FAULT
100.5 ORC COMMUNICATION FAULT
100.6SBEC/DEC/MCM COMMUNICATION
FAULT
200.0 AIRBAG LED SHORT
200.1 AIRBAG LED OPEN
200.2 ABS LED SHORT
200.3 ABS LED OPEN
200.6 EL INVERTER TIME-OUT
200.7 EATX MISMATCH
CALIBRATION TEST
The CLUSTER CALIBRATION table contains the
proper calibration points for each gauge. If the gauge
pointers are not calibrated, a problem exists in the
cluster. If any gauge is out of calibration, replace the
cluster.
CLUSTER CALIBRATION
SPEEDOMETER CALIBRATION POINT
1 0 MPH (0 KM/H)
2 20 MPH (40 KM/H)
3 60 MPH (100 KM/H)
4 100 MPH (160 KM/H)
TACHOMETER
1 0 RPM
2 1000 RPM
3 3000 RPM
4 6000 RPM
FUEL GAUGE
1 EMPTY
2 1/4 FILLED
3 1/2 FILLED
4 FULL
TEMPERATURE
GAUGE
1 COLD
2 1/4
3 3/4
4 HOT
ODOMETER SEGMENT TEST
If a segment in the odometer does not illuminate
normally, a problem exists in the display.
ELECTRONIC TRANSMISSION RANGE INDICATOR
SEGMENT TEST
If a segment in the transmission range indicator
does not illuminate normally, a problem exists in the
display.
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS
CONDITIONS
Refer to the following tables for possible problems,
causes, and corrections.
²INSTRUMENT CLUSTER DIAGNOSIS
²SPEEDOMETER DIAGNOSIS
²TACHOMETER DIAGNOSIS
²FUEL GAUGE DIAGNOSIS
²TEMPERATURE GAUGE DIAGNOSIS
²ODOMETER DIAGNOSIS
²ELECTRONIC GEAR INDICATOR DISPLAY
DIAGNOSIS
²MECHANICAL TRANSMISSION RANGE
INDICATOR (PRND21) DIAGNOSIS
8J - 2 INSTRUMENT CLUSTERRS
INSTRUMENT CLUSTER (Continued)
ProCarManuals.com

NOTE: Always check the functionality of the cluster
by running the self test prior to troubleshooting.
INSTRUMENT CLUSTER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
INSTRUMENT CLUSTER
INOPERATIVE. NO
RESPONSE FROM
INSTRUMENT CLUSTER.NO PCI BUS MESSAGES
FROM THE BCM.USE A DRB IIITSCAN TOOL TO CHECK THE BCM.
IF OK, LOOK FOR ANOTHER POSSIBLE CAUSE
FOR CLUSTER FAILURE. IF NOT OK, REFER TO
THE PROPER BODY DIAGNOSTIC PROCEDURES
MANUAL.
SPREAD TERMINAL(S)
ON WIRING HARNESS
CLUSTER CONNECTOR.REMOVE CLUSTER FROM INSTRUMENT PANEL
AND CHECK WIRING HARNESS CONNECTOR FOR
SPREAD TERMINAL. IF OK, LOOK FOR ANOTHER
POSSIBLE CAUSE FOR THE CLUSTER FAILURE. IF
NOT OK, REPAIR CONNECTOR.
BCM IS NOT RECEIVING
PROPER INPUT FROM
THE IGNITION SWITCH.1. USE A DRB IIITSCAN TOOL TO VERIFY IGNITION
SWITCH STATUS INTO THE BCM. IF NOT OK, GO
TO STEP (2). IF OK, LOOK AT ANOTHER POSSIBLE
CAUSE OF FAILURE.
2. CHECK IGNITION SWITCH FUNCTION AND
WIRING.
INTERNAL CLUSTER
FAILURE.REPLACE CLUSTER.
WAKE UP CIRCUIT
FAULTY.VERIFY CONTINUITY OF WAKE UP CIRCUIT FROM
BCM TO MIC. CIRCUIT SHALL BE LOW WHENEVER
BCM IS AWAKE.
POWER OR GROUND
MISSING.IF NO RESPONSE FROM THE MIC, CHECK FOR
POWER AND GROUND AT THE MIC CONNECTOR.
REFER TO WIRING DIAGRAMS FOR CONNECTOR
CALL OUTS.
RSINSTRUMENT CLUSTER8J-3
INSTRUMENT CLUSTER (Continued)
ProCarManuals.com

RED BRAKE WARNING
INDICATOR
DESCRIPTION
The red BRAKE warning indicator (lamp) is
located in the instrument panel cluster and is used to
indicate a low brake fluid condition or that the park-
ing brake is applied. In addition, the brake warning
indicator is turned on as a bulb check by the ignition
switch every time the ignition switch is placed in the
crank position.
OPERATION
The red BRAKE warning indicator (lamp) is sup-
plied a 12-volt ignition feed anytime the ignition
switch is on. The bulb is then illuminated by com-
pleting the ground circuit either through the switch
on the parking brake lever, the brake fluid level
switch in the master cylinder reservoir, or the igni-
tion switch when it is placed in the crank position.
RSINSTRUMENT CLUSTER8J-13
ProCarManuals.com