tow CHRYSLER VOYAGER 1996 Workshop Manual

29). The increase in electrode gap will be consider-
ably in excess of 0.001 in per 1000 miles of operation.
This suggests that a plug with a cooler heat range
rating should be used. Over advanced ignition tim-
ing, detonation and cooling system malfunctions also
can cause spark plug overheating.
THROTTLE POSITION SENSOR
To perform a complete test of the this sensor and
its circuitry, refer to the DRB scan tool and appropri-
ate Powertrain Diagnostics Procedures manual. To
test the throttle position sensor only, refer to the fol-
lowing:
The Throttle Position Sensor (TPS) can be tested
with a digital voltmeter (DVM). The center terminal
of the sensor is the output terminal. One of the other
terminals is a 5 volt supply and the remaining ter-
minal is ground.
Connect the DVM between the center and sensor
ground terminal. Refer to Group 8W - Wiring Dia-
grams for correct pinout.With the ignition switch in the ON position, check
the output voltage at the center terminal wire of the
connector. Check the output voltage at idle and at
Wide-Open-Throttle (WOT). At idle, TPS output volt-
age should be approximately 0.38 volts to 1.2 volts.
At wide open throttle, TPS output voltage should be
approximately 3.1 volts to 4.4 volts. The output volt-
age should gradually increase as the throttle plate
moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM
connections before replacing the TPS.
SERVICE PROCEDURES
SPARK PLUG GAP ADJUSTMENT
Check the spark plug gap with a gap gauge. If the
gap is not correct, adjust it by bending the ground
electrode (Fig. 30).
CAUTION: The Platinum pads can be damaged dur-
ing the measurement of checking the gap if extreme
care is not used.
Refer to 3.3/3.8L Spark Plug Gap Measurment in
this section.
POWERTRAIN CONTROL MODULE
REMOVAL
(1) Disconnect both cables from battery, negative
cable first.
(2) Remove 2 screws holding Power Distribution
Center (PDC) to bracket (Fig. 31).
(3) Remove heat shield from battery (Fig. 32).
(4) Remove nut and clamp holding battery to bat-
tery tray (Fig. 33).
(5) Remove battery from vehicle.
(6) Rotate PDC toward center of vehicle to remove
from rear bracket (Fig. 34).
Fig. 27 Chipped Electrode Insulator
Fig. 28 Preignition Damage
Fig. 29 Spark Plug Overheating
NSIGNITION SYSTEM 8D - 13
DIAGNOSIS AND TESTING (Continued)

REMOVAL AND INSTALLATION
SPARK PLUG CABLE SERVICEÐ2.4L
The cables insulate the spark plugs and covers the
top of the spark plug tube (Fig. 6). To remove the
cables, lightly grasp the top of the cable. Rotate the
insulator 90É and pull straight up. To replace the
cables, disconnect the cable from the ignition coil.
Ensure the #1 and #4 cables run under the #2
and #3 ignition coil towers. Keep #4 cable away
from the oil fill cap.
SPARK PLUG SERVICE
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them inthe appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs orshort cir-
cuit the cables to ground.
Never Wire Brush Spark Plugs.The spark plug
insulator tip is harder than the bristles of wire
brushes. Bristles of wire brushes can leave a conduc-
tive, metallic film on the insulator which could lead
to conductive deposits. Conductive deposits can cause
spark plug failure and engine misfire. Use a jewelers
file to remove deposits from the electrode gap or use
a spark plug cleaning machine to clean spark plugs.
REMOVAL
Always remove cables by grasping at the boot,
rotating the boot 1/2 turn, and pulling straight back
in a steady motion.
(1) Prior to removing the spark plug, spray com-
pressed air around the spark plug hole and the area
around the spark plug.
(2) Remove the spark plug using a quality socket
with a foam insert.
(3) Inspect the spark plug condition. Refer to
Spark Plug Condition in this section.
INSTALLATION
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 N´m (20 ft. lbs.)
torque.
(3) Install spark plug cables over spark plugs. A
click will be heard and felt when the cable properly
attaches to the spark plug.
IGNITION COILÐ2.4L
REMOVAL
REMOVAL
(1) Remove spark plug cables from coil (Fig. 7).
Always twist the coil boots to break the seal with the
coil and pull straight back on the boot.
(2) Remove ignition coil electrical connector.
(3) Remove ignition coil mounting bolts, throttle
cable bracket or clip.
(4) Remove ignition coil.
INSTALLATION
(1) Reverse the above procedure for installation.
Tighten mounting screws to 12 N´m (105 in. lbs.)
torque.
(2) Transfer ignition cables to new coil pack. The
coil pack towers and cables are numbered with cylin-
der identification.
Fig. 5 Intake Air Temperature Sensor
Fig. 6 Spark Plug Cables
8D - 18 IGNITION SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

SPECIFICATIONS
IGNITION COIL
SPARK PLUG
TORQUE
DESCRIPTION......................TORQUE
2.4L Target Magnet Screw.......3N´m(30in.lbs.)
2.4L Camshaft Position Sensoe Screw . .9 N´m (80 in.
lbs.)
Ignition Switch...............2N´m(17in.lbs.)
Spark Plugs.................28N´m(60in.lbs.)
SPARK PLUG CABLE RESISTANCEÐ2.4L
Coil ManufacturePrimary Resistance at 21ÉC-27ÉC
(70ÉF-80ÉF)Secondary Resistance at 21ÉC-
27ÉC (70ÉF-80ÉF)
Weastec (Steel Towers) 0.45 to 0.65 Ohms 7,000 to 15,800 Ohms
Coil Polarity
Engine Spark Plug Gap Thread Size
2.4L RC12YC5 0.048 TO 0.053 14mm (3/4 in.) reach
CABLE Maximum
Resistance
#1 & #4 4.2K ohms
#2 & #3 3.2K ohms
8D - 22 IGNITION SYSTEMNS

DISASSEMBLY AND ASSEMBLY
DISTRIBUTORÐ3.0L
REMOVAL
(1) Disconnect distributor connector from distribu-
tor (Fig. 6).
(2) Loosen distributor cap retaining screws.
(3) Lift cap of off distributor.
(4) Rotate engine crankshaft until the distributor
rotor points to the intake manifold plenum. Scribe a
mark on the plenum in line with the rotor. The scribe
line indicates where to position the rotor when rein-
stalling the distributor.
(5) Remove distributor hold down nut (Fig. 7).
(6) Carefully lift the distributor from the engine.
INSTALLATION
(1) Position distributor in engine. Make certain
that the O-ring is properly seated on distributor. If
O-ring is cracked or nicked replace with new one.
(2) Carefully engage distributor drive with gear on
camshaft. When the distributor is installed properly,
the rotor will be in line with previously scribe line on
air intake plenum.If engine was cranked while
distributor was removed, it will be necessary to
establish proper relationship between the dis-
tributor shaft and Number 1 piston position as
follows:
(a) Rotate the crankshaft until number one pis-
ton is at top of compression stroke.
(b) Rotate rotor to number one rotor terminal
(Fig. 8).
(c) Lower the distributor into the opening,
engaging distributor drive with drive on camshaft.
With distributor fully seated on engine, rotor
should be under the number 1 terminal.
(3) Install the distributor cap. Ensure sure all high
tension wires are firmly in the cap towers.
(4) Install hold-down nut and tighten (Fig. 7).
(5) Connect distributor electrical connector to dis-
tributor (Fig. 6).
CLEANING AND INSPECTION
DISTRIBUTOR CAP
Remove the distributor cap and inspect the inside
for flashover, cracking of carbon button, lack of
spring tension on carbon button, cracking of cap, and
burned, worn terminals (Fig. 9). Also check for bro-
ken distributor cap towers. If any of these conditions
are present the distributor cap and/or cables should
be replaced.
Fig. 6 Distributor Electrical ConnectorÐ3.0L Engine
Fig. 7 Distributor Hold-Down
Fig. 8 Distributor Cap Terminal Routing, View from
TopofCap
8D - 26 IGNITION SYSTEMNS

When replacing the distributor cap, transfer spark
plug wires from the original cap to the new cap one
at a time. Ensure that each wire is installed into the
tower of the new cap that corresponds to its tower
position in the original cap. Fully seat the wires into
the towers. If necessary, refer to the engine firing
order diagram.
Light scaling of the terminals can be cleaned with
a sharp knife. If the terminals are heavily scaled,
replace the distributor cap.
A cap that is greasy, dirty or has a powder-like
substance on the inside should be cleaned with asolution of warm water and a mild detergent. Scrub
the cap with a soft brush. Thoroughly rinse the cap
and dry it with a clean soft cloth.
DISTRIBUTOR ROTORÐ3.0L
Replace the rotor if it is cracked, the tip is exces-
sively burned or heavily scaled (Fig. 10).
SPECIFICATIONS
SPARK PLUG
TORQUE
DESCRIPTION......................TORQUE
Distributor Hold Down........14N´m(124 in. lbs.)
Ignition Coil Bracket..........10N´m(96in.lbs.)
Ignition Switch...............2N´m(17in.lbs.)
Spark Plugs.................28N´m(60in.lbs.)
SPARK PLUG CABLE RESISTANCEÐ3.0L
Fig. 9 Distributor Cap InspectionÐTypical
Fig. 10 Rotor InspectionÐTypical
Engine Spark Plug Gap Thread Size
3.0L RN11YC4 0.039 TO 0.044 14mm (3/4 in.) reach
CABLE Maximum
Resistance
#1 14.0K ohms
#2 10.4K ohms
#3 14.9K ohms
#4 11.5K ohms
#5 17.5K ohms
#6 10.3K ohms
Coil Lead 11.1K ohms
NSIGNITION SYSTEM 8D - 27
CLEANING AND INSPECTION (Continued)

(5) Install intake strut bolt to cylinder head at cyl-
inder head.
(6) Tighten bolt to intake strut at intake.
(7) Tighten bolt at cylinder head.
(8) Install the resonator.
SPARK PLUG #1
REMOVAL
(1) Remove the accessory drive belt, refer to Group
7, Cooling.
(2) Remove the 4 bolts from the upper half of the
generator bracket.
(3) Push the Generator rearward.
(4) Grasp the spark plug boot/shield assembly as
close as possible to the spark plug.Twist the boot/
shield assembly slightly to break its seal with
the plug and pull straight out. Do not use pli-
ers, pull on the ignition cable, or pull the spark
plug boot at an angle.This could damage the
spark plug insulator, terminal, or the insulation.
Wipe spark plug insulator clean with a dry cloth
before installation.
(5) Remove spark plug
INSTALLATION
(1) Install spark plug and tighten to 28 N´m (20 ft.
lbs.).
(2) When installing the spark plug cables, make
sure the coil or spark plug insulator and terminals
are fully seated. Aclick sound should be heard or
felt when the terminals are properly attached.
(3) Pull Generator back into place.
(4) Install upper Generator bracket with the 4
bolts.
(5) Install the accessory drive belt, refer to Group
7, Cooling.
IGNITION COIL
REMOVAL
(1) Remove spark plug cables from coil (Fig. 2).
Always twist the spark plug boots to break the seal
with the plug and pull straight back on the boot.
(2) Remove ignition coil electrical connector.
(3) Remove ignition coil mounting screws.
(4) Remove ignition coil.
INSTALLATION
(1) Reverse the above procedure for installation.
Tighten mounting screws to 12 N´m (105 in. lbs.)
torque.
(2) Transfer spark plug cables to new coil pack.
The coil pack towers and cables are numbered with
the cylinder identification.
CRANKSHAFT POSITION SENSOR
REMOVAL
(1) Raise and support vehicle.
(2) Disconnect crankshaft position sensor electrical
connector from the wiring harness connector (Fig. 3).
(3) Remove crankshaft position sensor retaining
bolt.
(4) Pull crankshaft position sensor straight up out
of the transaxle housing.
INSTALLATION
NOTE: If the removed sensor is to be reinstalled,
clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the sensor face before
installation. If the sensor is being replaced, confirm
that the paper spacer is attached to the face of the
new sensor (Fig. 4).
(1) Install sensor in transaxle and push sensor
down until contact is made with the drive plate.
Fig. 2 Ignition Coil Removal
Fig. 3 Crankshaft Position Sensor Connector
8D - 30 IGNITION SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Disconnect electrical connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensor.
INSTALLATION
(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.
SPECIFICATIONS
IGNITION COILFig. 12 Knock Sensor
Coil ManufacturePrimary Resistance at 21ÉC-27ÉC
(70ÉF-80ÉF)Secondary Resistance at 21ÉC-
27ÉC (70ÉF-80ÉF)
Weastec (Aluminum Towers) 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms
Diamond Electric (Brass Towers) 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms
Coil PolarityCoil Polarity
NSIGNITION SYSTEM 8D - 33
REMOVAL AND INSTALLATION (Continued)

The instrument cluster is equipped with the follow-
ing warning lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
NS vehicle instrument clusters are equipped with a
self diagnostic test feature to help identify electronic
problems. Prior to any test, perform Self Diagnostic
Test. The self diagnostic system monitors the CCD
bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in
the odometer window of the cluster.
The following CCD bus messages are continuously
monitored by the diagnostic system:
²Body Control Module
²Powertrain Control Module
²Transmission Control Module, if equipped
HEADLAMP SWITCH
Using a Digital Multimeter, equipped with a diode
test to perform the Headlamp Switch Test below (Fig.
1).
Switch position possibilities are open (no continu-
ity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine
meter setting. If Headlamp Switch is not within spec-
ifications replace as necessary.
The Chrysler Town and Country is available with
optional Automatic Headlamps. For diagnosis, refer
to the proper Body Diagnostic Procedures Manual.
SELF DIAGNOSTIC TEST
To activate self diagnostic program:
(1) With the ignition switch in the OFF position,
depress the TRIP and RESET buttons.
(2) While holding the TRIP and RESET button
turn the ignition switch to the ON position.
(3) Continue to hold the TRIP and RESET buttons
until the word CODE appears in the odometer win-
dows (about five seconds) then release the buttons. If
a problem exists, the system will display Diagnostic
Trouble Codes (DTC's). If no problem exists, the code
999 (End Test) will momentarily appear.
DIM TEST
When CHEC-0 is displayed in the odometer win-
dow, the cluster's vacuum fluorescent (VF) displayswill dim down. If the VF display brightness does no
change, a problem exists in the cluster.
Fig. 1 Headlamp Switch Test
8E - 2 INSTRUMENT PANEL AND SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)

(2) Connect wire connector into back of instrument
cluster.
(3) Position instrument cluster in instrument
panel.
(4) Install instrument cluster mounting screws to
instrument panel.
(5) Install instrument cluster bezel.
INSTRUMENT CLUSTER WITH MECHANICAL
TRANSMISSION RANGE INDICATOR
REMOVAL
(1) Remove the lower steering column cover.
(2) Remove the metal knee blocker panel.
(3) Disconnect the transmission range indicator
cable end from shift lever by flexing the HOOP on
the transmission shift cable rearward and slip the
indicator cable loop off the lever pin (Fig. 23).
(4) Disconnect the clip holding the indicator cable
to the steering column/transmission shift cable
bracket.
(5) Remove the instrument cluster bezel.
(6) Rotate top of the cluster rearward.
(7) Disconnect the wire connector from back of the
instrument cluster.
(8) Remove the instrument cluster carefully while
guiding the range indicator cable and guide tube
through the opening to avoid any damage (Fig. 24).
INSTALLATION
(1) Verify the free travel of the range indicator
cable from P to 1 by gently pulling on the cable and
relaxing the cable. DO NOT SNAP THE CABLE
ONCE IT IS PULLED.
(2) Position the instrument cluster in instrument
panel and route the indicator cable and guide tube
through the opening in the instrument panel. Posi-tion the cluster by leading the bottom in first, con-
nect the wire connector, and rotate upward.
(3) Install the screws to hold the instrument clus-
ter to the instrument panel.
(4) Install the instrument cluster bezel.
(5) Connect the clip to hold the indicator cable to
steering column/transmission shift cable bracket. The
indicator cable and guide tube should BOW towards
the passenger side of the vehicle (Fig. 25).
(6) Connect indicator cable loop end to shift lever
by flexing the hoop on the transmission shift cable
rearward, then slip the indicator cable loop over the
shift lever pin and into the groove.
(7) Assuming the transmission shift system is
properly adjusted, place the shift lever in neutral N
position.
NOTE: The parking brake should have been
engaged for safety purposes.
Fig. 22 Instrument Panel ±Electronic Transmission
Range IndicatorFig. 23 Range Indicator
Fig. 24 Removing and Installing Cluster
8E - 24 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)

TURN SIGNAL AND FLASHERS
CONTENTS
page page
GENERAL INFORMATION
COMBINATION FLASHER.................. 1
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
COMBINATION FLASHER / DAYTIME
RUNNING LAMPS (DRL) MODULE......... 2
COMBINATION FLASHER FUNCTION......... 1DIAGNOSIS AND TESTING
COMBINATION FLASHER WITH / WITHOUT
DAYTIME RUNNING LAMPS MODULEÐ
CIRCUIT DIAGNOSTICS.................. 3
TURN SIGNAL MULTI-FUNCTION SWITCH.... 2
REMOVAL AND INSTALLATION
COMBINATION FLASHER WITH / WITHOUT
DRL MODULE........................ 11
MULTI-FUNCTION SWITCH............... 11
GENERAL INFORMATION
INTRODUCTION
The turn signals are actuated with a lever on the
left side of the steering column just ahead of the
steering wheel. The signals are automatically turned
off by a canceling cam (two lobes molded to the clock-
spring mechanism). The cam comes in contact with
the cancel actuator on the turn signal (multi-func-
tion) switch assembly. Either cam lobe, pushing on
the cancel actuator, returns the switch to the OFF
position.
Lane change signaling is actuated by applying par-
tial turn signal stalk movement toward the direction
desired until the indicator lamps flashes in the
instrument cluster. When the switch stalk is released
the stalk will spring back into the neutral position
turning OFF the turn signal.
With the ignition switch ON and the turn signal
switch stalk actuated left or right, current flows
through the:
²Combination flasher
²Multi-function switch
²Turn indicator lamp
²Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a
distance of approximately 0.5 mile with the turn sig-
nal ON.
COMBINATION FLASHER
The Turn Signal/Hazard Warning Flasher is a
module providing the vehicle with turn signal and
hazard warning functions and has been designed
with internal relays to take advantage of low current
switching requirements in the vehicle. It is plugged
into the Junction Block at position 4 (Fig. 1), where
all wiring associated with its operation is terminated.The Junction Block is adjacent to and left of the
steering column of the vehicle.
To gain access to the flasher, remove the lower
steering column cover and knee blocker. Refer to
Group 8E, Instrument Panel and Systems for
removal procedures.
DESCRIPTION AND OPERATION
COMBINATION FLASHER FUNCTION
The Turn Signal/Hazard Warning Flasher is a
module providing turn signal, hazard warning func-
tions and has been designed with internal relays to
Fig. 1 Combination Flasher Location
NSTURN SIGNAL AND FLASHERS 8J - 1