CHRYSLER VOYAGER 1996 Service Manual

CHARGING SYSTEM TEST
NSCHARGING SYSTEM 8C - 5
DIAGNOSIS AND TESTING (Continued)

OVERCHARGE TEST
8C - 6 CHARGING SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

TEST
(1) Perform the previous test Preparation.
(2) Fully engage the parking brake.
(3) Start engine.
(4) Bring engine speed to 2500 rpm.
(5) With engine speed held at 2500 rpm, slowly
adjust the rheostat control (load) on the tester to
obtain the highest amperage reading. Do not allow
voltage to drop below 12 volts. Record the reading.
This load test must be performed within 15 sec-
onds to prevent damage to test equipment.On
certain brands of test equipment, this load will be
applied automatically. Refer to the operating manual
supplied with test equipment.
(6) The ammeter reading must meet the Minimum
Test Amps specifications as displayed in the Genera-tor Ratings chart. This can be found in the Specifica-
tions section at the end of this group. A label stating
a part reference number is attached to the generator
case. On some engines this label may be located on
the bottom of the case. Compare this reference num-
ber to the Generator Ratings chart.
(7) Rotate the load control to the OFF position.
(8) Continue holding engine speed at 2500. If EVR
circuitry is OK, amperage should drop below 15±20
amps. With all electrical accessories and vehicle
lighting off, this could take several minutes of engine
operation. If amperage did not drop, refer to the
appropriate Powertrain Diagnostic Procedures man-
ual for testing.
(9) Remove volt/amp tester.
If minimum amperage could not be met, refer to
the appropriate Powertrain Diagnostic Procedures
manual for testing.
ON-BOARD DIAGNOSTIC SYSTEM TEST
GENERAL INFORMATION
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the OBD system. Some
circuits are checked continuously and some are
checked only under certain conditions.
If the OBD system senses that a monitored circuit
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed
to clear the memory after 50 engine starts if the
problem does not occur again.
DIAGNOSTIC TROUBLE CODES
Refer to Group 25, On Board Diagnostic for more
information. A DTC description can be read using the
DRB scan tool. Refer to the appropriate Powertrain
Diagnostic Procedures manual for information.
A DTC does not identify which component in a cir-
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-
cedures be followed in sequence, to understand what
caused a DTC to be set.
ERASING DIAGNOSTIC TROUBLE CODES
The DRB Scan Tool must be used to erase a DTC.
Fig. 1 Generator Terminals
Fig. 2 Battery Voltage TestÐTypical
NSCHARGING SYSTEM 8C - 7
DIAGNOSIS AND TESTING (Continued)

VOLTAGE DROP TEST
8C - 8 CHARGING SYSTEMNS

REMOVAL AND INSTALLATION
GENERATORÐ2.4L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 3).
(3) Remove accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(4) Disconnect the push-in field wire connector
from back of generator (Fig. 4).
(5) Remove nut holding B+ wire to terminal on
back of generator.
(6) Separate B+ wire from generator terminal.
(7) Remove nut holding top of generator to adjust-
able T-bolt (Fig. 5).
(8) Remove bolt holding bottom generator pivot to
lower mount.
(9) Remove generator.
INSTALLATION
(1) Place generator in position on vehicle.
(2) Install bolt to hold bottom generator pivot to
lower mount.(3) Install nut to hold top of generator to adjust-
able T-bolt.
(4) Place B+ wire in position on generator termi-
nal.
(5) Install nut to hold B+ wire to terminal on back
of generator.
(6) Connect the push-in field wire connector onto
back of generator.
(7) Install accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(8) Connect battery negative cable.
(9) Verify generator charge rate.
GENERATORÐ3.0L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 3).
(3) Remove windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
(4) Remove accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(5) Remove bolt holding top of generator to mount
bracket (Fig. 6).
(6) Remove bolt holding bottom of generator to
lower pivot bracket (Fig. 4).
(7) Disengage push-in field wire connector from
back of generator.
(8) Remove nut holding B+ wire terminal to back
of generator.
(9) Remove B+ terminal from generator.
INSTALLATION
(1) Place B+ terminal in position on generator.
(2) Install nut to hold B+ wire terminal to back of
generator
(3) Connect the push-in field wire connector into
back of generator.
Fig. 3 Removal/Installation of Battery Cables
Fig. 4 Wire Connectors
Fig. 5 Generator±2.4L Engine
NSCHARGING SYSTEM 8C - 9

(4) Install bolt to hold bottom of generator to lower
pivot bracket.
(5) Install bolt to hold top of generator to mount
bracket.
(6) Install accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(7) Install windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
(8) Connect battery negative cable.
(9) Verify generator charge rate.
GENERATORÐ3.3/3.8 L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 3).
(3) Remove windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
(4) Remove accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(5) Remove bolt holding top of generator mount
bracket to engine air intake plenum (Fig. 7).
(6) Remove bolts holding outside of generator
mount bracket to generator mount plate.
(7) Remove bolt holding top of generator to mount
bracket.
(8) Remove generator mount bracket from vehicle.
(9) Rotate generator toward rear dash panel.
(10) Disconnect the push-in field wire connector
from back of generator (Fig. 6).
(11) Remove nut holding B+ wire terminal to back
of generator.
(12) Separate B+ terminal from generator.
(13) Remove bolt holding bottom of generator to
lower pivot bracket (Fig. 8).
(14) Remove generator from vehicle (Fig. 9).
INSTALLATION
(1) Place generator in position on vehicle.
Fig. 6 Generator±3.0L EngineFig. 7 Generator Mounting Bracket
Fig. 8 Generator pivot Bolt
Fig. 9 Generator±3.3/3.8 L Engine
8C - 10 CHARGING SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(2) Install bolt to hold bottom of generator to lower
pivot bracket.
(3) Place B+ terminal in position on generator.
(4) Install nut to hold B+ wire terminal to back of
generator.
(5) Connect the push-in field wire connector into
back of generator.
(6) Rotate generator forward away from dash
panel.
(7) Place generator mount bracket in position on
vehicle.
(8) Install bolt to hold top of generator to mount
bracket.
(9) Install bolts to hold outside of generator mount
bracket to generator mount plate.
(10) Install bolt to hold top of generator mount
bracket to engine air intake plenum.
(11) Install accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(12) Install windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
(13) Connect battery negative cable.
(14) Verify generator charge rate.SPECIFICATIONS
GENERATOR
Part number is located on the side of the generator.
TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt.......14N´m(125 in. lbs.)
Generator Mounting Bolts......54N´m(40ft.lbs.)
Generator B+ Terminal.........9N´m(75in.lbs.)
Starter Mounting Bolts.........54N´m(40ft.lbs.)
Starter Solenoid Battery Nut. . . .10 N´m (90 in. lbs.)
TypePart Num-
berAmperage out-
put
Nippondenso 90 A
HS4727220 86 Amp
Nippondenso 120 A
HS4727221 98 Amp
NSCHARGING SYSTEM 8C - 11
REMOVAL AND INSTALLATION (Continued)

IGNITION SYSTEM
CONTENTS
page page
GENERAL INFORMATION................... 1
2.4L ENGINE............................ 16
3.0L ENGINE............................ 233.3/3.8L ENGINE........................ 28
IGNITION SWITCH AND LOCK CYLINDER..... 35
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
AUTOMATIC SHUTDOWN (ASD) RELAY....... 4
CAMSHAFT POSITION SENSOR............. 5
CRANKSHAFT POSITION SENSOR........... 5
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR.............................. 6
IGNITION COIL.......................... 4
IGNITION SYSTEM....................... 2
INTRODUCTION......................... 1
KNOCK SENSOR......................... 7
LOCK KEY CYLINDER..................... 7
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR.............................. 6
POWERTRAIN CONTROL MODULE........... 1
SPARK PLUG CABLE...................... 3
SPARK PLUGSÐ2.4/3.0L................... 2
SPARK PLUGSÐ3.3/3.8L................... 2
THROTTLE POSITION SENSOR (TPS)........ 7DIAGNOSIS AND TESTING
CAMSHAFT POSITION SENSOR AND
CRANKSHAFT POSITION SENSOR......... 11
CHECK COIL TESTÐ2.4L.................. 9
CHECK COIL TESTÐ3.3/3.8L................ 9
ENGINE COOLANT TEMPERATURE SENSOR . . 11
FAILURE TO START TEST................. 10
IGNITION TIMING PROCEDURE............ 11
INTAKE AIR TEMPERATURE SENSOR........ 11
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR TEST........................ 11
SPARK PLUG CONDITION................. 11
TESTING FOR SPARK AT COILÐ2.4/3.3/3.8L
ENGINES............................. 8
TESTING FOR SPARK AT COILÐ3.0L......... 8
THROTTLE POSITION SENSOR............ 13
SERVICE PROCEDURES
IGNITION TIMING PROCEDURE............ 15
POWERTRAIN CONTROL MODULE.......... 13
SPARK PLUG GAP ADJUSTMENT........... 13
GENERAL INFORMATION
INTRODUCTION
This group describes the ignition systems for the
2.4, 3.0, and 3.3/3.8L engines.
On Board Diagnostics is described in Group 25 -
Emission Control Systems.
Group 0 - Lubrication and Maintenance, contains
general maintenance information for ignition related
items. The Owner's Manual also contains mainte-
nance information.
POWERTRAIN CONTROL MODULE
The ignition system is regulated by the Powertrain
Control Module (PCM) (Fig. 1). The PCM supplies
battery voltage to the ignition coil through the Auto
Shutdown (ASD) Relay. The PCM also controls
ground circuit for the ignition coil. By switching the
ground path for the coil on and off, the PCM adjusts
ignition timing to meet changing engine operating
conditions.
During the crank-start period the PCM advances
ignition timing a set amount. During engine opera-
tion, the amount of spark advance provided by the
PCM is determined by the following input factors:
NSIGNITION SYSTEM 8D - 1

²available manifold vacuum
²barometric pressure
²engine coolant temperature
²engine RPM
²intake air temperature (2.4L only)
²throttle position
The PCM also regulates the fuel injection system.
Refer to the Fuel Injection sections of Group 14.
IGNITION SYSTEM
NOTE: The 2.4, 3.0 and 3.3/3.8L engines use a fixed
ignition timing system. Basic ignition timing is not
adjustable. All spark advance is determined by the
Powertrain Control Module (PCM).
The distributorless ignition system used on 2.4 and
3.3/3.8L engines is refered to as the Direct Ignition
System (DIS). The system's three main components
are the coil pack, crankshaft position sensor, and
camshaft position sensor. The crankshaft position
sensor and camshaft position sensor are hall effect
devices.
The 3.0L engine uses a distributor, crankshaft sen-
sor and ignition coil. The system's main components
are the distributor, distributor pickup, camshaft sig-
nal, crankshaft signal and ignition coil.
SPARK PLUGSÐ2.4/3.0L
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.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O - Lubrication and Maintenance.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
fouled. Refer to the Spark Plug Condition section of
this group. After cleaning, file the center electrode
flat with a small flat point file or jewelers file. Adjust
the gap between the electrodes (Fig. 2) to the dimen-
sions specified in the chart at the end of this section.
Special care should be used when installing spark
plugs in the 2.4L cylinder head spark plug wells. Be
sure the plugs do not drop into the wells, damage to
the electrodes can occur.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap. Overtightening can
also damage the cylinder head. Tighten spark plugs
to 28 N´m (20 ft. lbs.) torque.SPARK PLUGSÐ3.3/3.8L
The 3.3/3.8L engines utilize platinum spark plugs.
Refer to the maintenance schedule in Group 0 of this
service manual.
Fig. 1 Powertrain Control Module
Fig. 2 Setting Spark Plug Electrode Gap
8D - 2 IGNITION SYSTEMNS
GENERAL INFORMATION (Continued)