Index CHRYSLER VOYAGER 1996 Repair Manual

ENGINE
CONTENTS
page page
2.0L SOHC ENGINE...................... 12.5L VM DIESEL....................... 40
2.0L SOHC ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 3
ENGINE IDENTIFICATION................. 1
ENGINE LUBRICATION SYSTEM............ 2
GENERAL SPECIFICATION................ 2
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE........ 3
SERVICE PROCEDURES
CRANKSHAFT END PLAY................. 6
CYLINDER BORE AND PISTON SIZING....... 4
FITTING CONNECTING RODS.............. 5
FITTING CRANKSHAFT BEARINGS.......... 6
FITTING PISTON RINGS.................. 4
REMOVAL AND INSTALLATION
CAMSHAFT OIL SEAL................... 12
CAMSHAFT............................ 7
CRANKSHAFT OIL SEALÐREAR........... 20
CRANKSHAFT......................... 21
CYLINDER HEAD COVER................. 6
CYLINDER HEAD....................... 10
FRONT CRANKSHAFT OIL SEAL........... 18
OILFILTER ........................... 24
OIL FILTER ADAPTER................... 24OILPAN .............................. 17
OIL PUMP............................ 25
PISTON AND CONNECTING ROD.......... 25
ROCKER ARM/HYDRAULIC LASH ADJUSTER . . 8
SPARK PLUG TUBE...................... 7
TIMING BELT COVER................... 11
TIMING BELT SYSTEM.................. 13
VALVE SEALS AND SPRINGS IN VEHICLE . . . 10
VIBRATION DAMPER.................... 28
DISASSEMBLY AND ASSEMBLY
OIL PUMP............................ 29
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED.......................... 29
CLEANING AND INSPECTION
CYLINDER BLOCK AND BORE............ 34
CYLINDER HEAD AND CAMSHAFT
JOURNALS.......................... 32
OIL PUMP............................ 32
SPECIFICATIONS
ENGINE 2.0L SOHC..................... 34
TORQUE CHART 2.0L SOHC.............. 36
SPECIAL TOOLS
ENGINE 2.0L SOHC..................... 36
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
The engine identification number is located on the
left rear of the cylinder block behind starter (Fig. 1).
Fig. 1 Engine Identification SOHC
NS/GSENGINE 9 - 1

(3) Remove front timing belt cover (Fig. 31).
CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt.
(4) Loosen timing belt tensioner fasteners (Fig. 33)
and remove timing belt and tensioner.
CAUTION: Do not loosen, tighten, or remove the
tensioner pivot bolt (Fig. 32).
CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATION
ÐSOHC ENGINE
(1) When tensioner is removed from the engine it
is necessary to compress the plunger into the ten-
sioner body.(2) Place the tensioner into a vise equipped with
soft jaws and slowly compress the plunger (Fig. 34).
CAUTION: Index the tensioner in the vise the same
way it is installed on the engine. This is to ensure
proper pin orientation when tensioner is installed
on the engine.
(3) When plunger is compressed into the tensioner
body install a 1.9 mm (5/64) allen wrench or pin
through the body and plunger to retain plunger in
place until tensioner is installed.
(4) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing,
then back off to 3 notches before TDC (Fig. 35).
Fig. 30 Crankshaft DamperÐRemoval
Fig. 31 Timing Belt Cover
Fig. 32 Tensioner Pulley Assembly
Fig. 33 Remove Timing Belt
9 - 14 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

2.5L VM DIESEL
INDEX
page page
GENERAL INFORMATION
ENGINE IDENTIFICATION................ 41
GENERAL SPECIFICATION............... 40
DESCRIPTION AND OPERATION
LUBRICATION SYSTEM.................. 41
DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐMECHANICAL....... 44
ENGINE DIAGNOSISÐPERFORMANCE..... 43
HYDRAULIC TAPPETS................... 47
SERVICE PROCEDURES
CHANGING ENGINE OIL AND FILTER....... 47
CHECKING OIL LEVEL................... 47
CRANKSHAFT END PLAY................ 50
FITTING PISTON RING.................. 50
TIMING PROCEDURE................... 49
VALVE AND SEAT REFACING............. 49
REMOVAL AND INSTALLATION
CAMSHAFT........................... 62
CAMSHAFT BEARINGS.................. 63
CRANKSHAFT MAIN BEARINGS........... 63
CRANKSHAFTÐREMOVAL............... 72
CYLINDER HEAD....................... 55
CYLINDER HEAD COVER................ 54
CYLINDER LINER...................... 72
ENGINE ASSEMBLY..................... 53
ENGINE MOUNTÐFRONT................ 51
ENGINE MOUNTÐREAR................. 52
ENGINE MOUNTÐRIGHT................ 51
HYDRAULIC TAPPETS................... 60
INJECTION PUMP...................... 61
MOUNTÐLEFT SIDE.................... 51
OIL FILTER ADAPTER AND OIL COOLER.... 68
OILPAN .............................. 66OIL PUMP............................ 67
OIL PUMP PRESSURE RELIEF VALVE...... 67
PISTONS AND CONNECTING ROD......... 68
REAR CRANKSHAFT OIL SEAL............ 72
ROCKER ARMS AND PUSH RODS......... 54
TIMING GEAR COVER................... 61
TIMING GEAR COVER OIL SEAL........... 61
VACUUM PUMP........................ 68
VALVE SPRINGSÐCYLINDER HEAD NOT
REMOVED.......................... 55
VALVES AND VALVE SPRINGSÐHEAD OFF . . 60
VIBRATION DAMPER.................... 61
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS................... 73
CLEANING AND INSPECTION
CRANKSHAFT......................... 77
CRANKSHAFT MAIN BEARING............ 77
CYLINDER HEAD....................... 75
CYLINDER HEAD COVERS............... 74
CYLINDER LINER...................... 78
HYDRAULIC TAPPETS................... 76
OILPAN .............................. 78
OIL PUMP............................ 76
PISTON AND CONNECTING ROD.......... 76
ROCKER ARMS AND PUSH RODS......... 74
TIMING GEAR COVER................... 75
VALVES AND VALVE SPRINGS............ 76
SPECIFICATIONS
2.5L VM DIESEL........................ 78
TORQUE............................. 80
SPECIAL TOOLS
2.5L VM DIESEL........................ 81
GENERAL INFORMATION
GENERAL SPECIFICATION
Type ........................425CLIEE (36B)
Displacement...................2.5L (2499 cc)
Bore.............................92.00 mm
Stroke............................94.00 mm
Compression Ratio....................20.95:1
Vacuum at Idle..........600mm/Hg (23.6 In/Hg)
Thermostat Opening................80ÉC62ÉC
Generator Rating............Bosch 50/120 Amp
Cooling System Capacity..............9.5Liter
Power Steering Capacity.............0.75 LiterType ........................425CLIEE (36B)
Engine Oil Capacity.....6.5Liters With Oil Filter
Change
Timing System . Pushrod Operated Overhead valves,
With Gear-Driven Camshaft.
Air Intake........................DryFilter
Fuel Feed...........Vacuum Pump Incorporated
in Injection Pump.
Fuel System.............Indirect Fuel Injection
(Precombustion Chamber)
Combustion Cycle....................4Stroke
Cooling System..................Water Cooled
Injection Pump.......Rotary Pump Electronically
Controlled.
9 - 40 ENGINENS/GS

FRAME AND BUMPERS
CONTENTS
page page
BUMPERS AND FASCIA.................... 1FRAME................................. 3
BUMPERS AND FASCIA
INDEX
page page
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA.................. 1
FRONT BUMPER REINFORCEMENT.......... 1REAR BUMPER FASCIA................... 2
REAR BUMPER REINFORCEMENT........... 2
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding fascia to headlamp
mounting panel at each side of grille.
(3) Hoist and support vehicle on safety stands.
(4) Remove front wheels. Refer to Group 22,
Wheels and Tires, for proper procedures and
sequence.
(5) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts holding front
fascia to fender. Refer to Group 23, Body, for proper
procedures.
(6) Remove bolts holding fascia to bottom of front
fenders (Fig. 1).
(7) Remove bolts holding bottom of fascia/air dam
to radiator closure panel.
(8) Disconnect fog lamp/parking and turn signal
lamp wire connector, if necessary.
(9) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Lower vehicle.
(3) Install bolts to hold fascia to headlamp mount-
ing panel at each side of grille.
(4) Raise vehicle.
(5) Install bolts to hold fascia to bottom of front
fenders (Fig. 1). The fascia should be flush to fender.(6) Install front wheelhouse splash shields fasten-
ers. Refer to Group 23, Body, for proper procedures.
(7) Install front wheels. Refer to Group 22, Wheels
and Tires, for proper procedures and tightening
sequence.
(8) Install bolts to hold bottom of fascia to radiator
closure panel.FRONT BUMPER REINFORCEMENT
REMOVAL
(1) Remove front bumper fascia.
(2) Support front bumper reinforcement on a suit-
able lifting device.
(3) Remove nuts holding front bumper reinforce-
ment to frame rail (Fig. 2).
Fig. 1 Front Bumper Fascia
NSFRAME AND BUMPERS 13 - 1

FRAME
INDEX
page page
REMOVAL AND INSTALLATION
FRONT CROSSMEMBER MOUNT BUSHINGS . . . 5
FRONT CROSSMEMBER................... 3SPECIFICATIONS
FRAME AND BODY OPENING DIMENSIONS.... 5
REMOVAL AND INSTALLATION
FRONT CROSSMEMBER
The front suspension crossmember must be
installed in the design location to achieve proper
front end suspension alignment. If the crossmember
is removed without applying reference marks on the
frame rails, align the crossmember according to the
dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through a MoparTParts supplier.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel. Refer to Group 8E, Instrument
Panel and Systems.
(3) Remove knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to airbag clock spring can result.
(5) Remove clinch bolt holding steering column
coupling to steering gear shaft (Fig. 1).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.
(7) Hoist and support vehicle on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the crossmember cou-
pling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut hold-
ing high pressure hose to back of pump.(13) Separate high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts holding anti-lock brake sensor
leads to crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar. Refer to Group 2, Suspension.
(18) Disconnect lower ball joints from lower control
arms. Refer to Group 2, Suspension.
(19) Remove bolt holding rear engine mount to
crossmember (Fig. 2).
(20) Using paint or grease pencil, mark outline of
crossmember on frame rails to aid installation.
(21) Support crossmember on suitable lifting
device (Fig. 4).
(22) Remove bolts holding crossmember to front
frame rails (Fig. 3).
(23) Remove crossmember from vehicle (Fig. 4).
Fig. 1 Steering Coupling Boot
NSFRAME AND BUMPERS 13 - 3

FRAME AND BUMPERS
CONTENTS
page
FRAME................................ 1
FRAME
INDEX
page page
REMOVAL AND INSTALLATION
FRONT TOW HOOK BRACKET............. 1REAR TOW HOOK BRACKET.............. 1
REMOVAL AND INSTALLATION
FRONT TOW HOOK BRACKET
REMOVAL
(1) Hoist and support vehicle. Refer to Group 0,
Lubrication and Maintenance, for proper lifting pro-
cedures.
(2) Remove screws holding the bottom of the front
fascia to the lower radiator crossmember.
(3) Remove front tow hook eyelet from front tow
hook bracket.
(4) Support engine and transaxle assembly using
suitable support stand.
(5) Remove bolts holding front tow hook bracket to
lower radiator crossmember.
(6) Separate front tow hook bracket from vehicle.
INSTALLATION
(1) Position front tow hook bracket to vehicle.
(2) Install bolts to hold front tow hook bracket to
lower radiator crossmember.
(3) Remove support stand from under engine and
transaxle assembly.
(4) Install front tow hook eyelet to front tow hook
bracket.
(5) Install screws to hold the bottom of the front
fascia to the lower radiator crossmember.(6) Lower vehicle.REAR TOW HOOK BRACKET
REMOVAL
(1) Hoist and support vehicle. Refer to Group 0,
Lubrication and Maintenance, for proper lifting pro-
cedure.
(2) Remove bolts holding rear tow hook bracket to
rear frame rail (Fig. 2).
Fig. 1 Front Tow Hook Bracket
NS/GSFRAME AND BUMPERS 13 - 1

FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM................... 4
FUEL INJECTION SYSTEM................. 29GENERAL INFORMATION................... 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CRUISING RANGE........................ 3
E-85 GENERAL INFORMATION.............. 2
ETHANOL FUEL (E-85).................... 2
FUEL REQUIREMENTS.................... 1
FUEL REQUIREMENTS.................... 2GASOLINE/OXYGENATE BLENDS............ 2
INTRODUCTION......................... 1
PCM REPLACEMENT..................... 1
REPLACEMENT PARTS.................... 3
STARTING.............................. 2
GENERAL INFORMATION
INTRODUCTION
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction Section at the front of
this service manual.
The Evaporation Control System, is also considered
part of the fuel system. The system reduces the emis-
sion of fuel vapor into the atmosphere.
The description and function of the Evaporation
Control System is found in Group 25 of this manual.
PCM REPLACEMENT
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW PCM WITH THE VEHICLES ORIGI-
NAL IDENTIFICATION NUMBER (VIN) AND
THE VEHICLES ORIGINAL MILEAGE. IF THIS
STEP IS NOT DONE A DIAGNOSTIC TROUBLE
CODE (DTC) MAY BE SET.
FUEL REQUIREMENTS
Your vehicle was designed to meet all emission reg-
ulations and provide excellent fuel economy when
using high quality unleaded gasoline.
Use unleaded gasolines having a minimum posted
octane of 87.
If your vehicle develops occasional light spark
knock (ping) at low engine speeds this is not harm-
ful. However; continued heavy knock at high speeds
can cause damage and should be reported to your
dealer immediately. Engine damage as a result of
heavy knock operation may not be covered by the
new vehicle warranty.
In addition to using unleaded gasoline with the
proper octane rating, those that contain detergents,
corrosion and stability additives are recommended.
Using gasolines that have these additives will help
improve fuel economy, reduce emissions, and main-
tain vehicle performance.
Poor quality gasoline can cause problems such as
hard starting, stalling, and stumble. If you experi-
ence these problems, try another brand of gasoline
before considering service for the vehicle.
NSFUEL SYSTEM 14 - 1

FUEL DELIVERY SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM.................. 4
FUEL INJECTORS........................ 5
FUEL LEVEL SENSOR..................... 5
FUEL PRESSURE REGULATOR.............. 5
FUEL PUMP MODULE..................... 4
FUEL TANK............................. 5
PRESSURE-VACUUM FILLER CAP........... 6
QUICK-CONNECT FITTINGS................ 6
DIAGNOSIS AND TESTING
FUEL INJECTORS........................ 9
FUEL LEVEL SENSOR..................... 9
FUEL PUMP PRESSURE TEST 2.4/3.3/3.8L..... 6
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.4/3.3/3.8L............... 11
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L ENGINE............. 11
HOSES AND CLAMPS.................... 12QUICK-CONNECT FITTINGS............... 12
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL................... 26
FUEL FILTER........................... 12
FUEL INJECTOR RAILÐ2.4L............... 18
FUEL INJECTOR RAILÐ3.0L............... 19
FUEL INJECTOR RAILÐ3.3/3.8L............ 21
FUEL INJECTORSÐ3.0L.................. 25
FUEL INJECTORÐ2.4L................... 24
FUEL INJECTORÐ3.3/3.8L................. 26
FUEL LEVEL SENSOR.................... 15
FUEL PRESSURE REGULATOR............. 14
FUEL PUMP INLET STRAINER............. 15
FUEL PUMP MODULE.................... 13
FUEL TANK............................ 17
THROTTLE CABLE...................... 27
SPECIFICATIONS
FUEL TANK CAPACITY................... 28
TORQUE.............................. 28
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
The front wheel drive van uses a plastic fuel tank
located on the left side of the vehicle.
The Fuel Delivery System consists of: the electric
fuel pump module, fuel filter, tubes/lines/hoses, fuel
rail, and fuel injectors.
The in-tank fuel pump module contains the fuel
pump and pressure regulator. The pump is serviced
as part of the fuel pump module. Refer to Fuel Pump
Module.
The fuel filter is a replaceable in-line filter. The fil-
ter attaches to a bracket mounted on top of the fuel
tank. Refer to the Maintenance Schedules in the
Introduction section of this manual for recommended
fuel filter replacement intervals.
A returnless fuel system is used on all vehicles.
Fuel is returned through the fuel pump module and
back to the fuel tank. A separate fuel return line
from the tank to the engine is no longer used.
FUEL PUMP MODULE
The fuel pump module is installed in the top of the
fuel tank (Fig. 1). The fuel pump module contains the
following:
²Electric fuel pump
²Fuel pump reservoir
²Inlet strainer²Fuel pressure regulator
²Fuel gauge sending unit
²Fuel supply line connection
The inlet strainer, fuel pressure regulator
and fuel level sensor are the only serviceable
items. If the fuel pump or electrical wiring har-
ness requires service, replace the fuel pump
module.
ELECTRIC FUEL PUMP
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The pump draws fuel through
a strainer and pushes it through the motor to the
outlet. The pump contains one check valve. The
Fig. 1 Fuel Pump Module
14 - 4 FUEL SYSTEMNS

FUEL INJECTION SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 30
MODES OF OPERATION.................. 30
DESCRIPTION AND OPERATION
AIR CONDITIONING (A/C) CLUTCH RELAYÐ
PCM OUTPUT......................... 41
AIR CONDITIONING PRESSURE
TRANSDUCERÐPCM INPUT............. 33
AIR CONDITIONING SWITCH SENSEÐ
PCM INPUT........................... 33
AUTOMATIC SHUTDOWN (ASD) SENSEÐ
PCM INPUT........................... 33
AUTOMATIC SHUTDOWN RELAYÐPCM
OUTPUT............................. 42
AUTOMATIC TRANSAXLE CONTROL
MODULEÐPCM OUTPUT................ 44
BATTERY VOLTAGEÐPCM INPUT........... 33
BRAKE SWITCHÐPCM INPUT.............. 33
CAMSHAFT POSITION SENSORÐPCM INPUT . 33
CCDBUS .............................. 32
CRANKSHAFT POSITION SENSORÐPCM
INPUT............................... 35
DATA LINK CONNECTORÐPCM OUTPUT..... 44
DUTY CYCLE EVAP CANISTER PURGE
SOLENOIDÐPCM OUTPUT.............. 43
ELECTRONIC EGR TRANSDUCER
SOLENOIDÐPCM OUTPUT.............. 43
ENGINE COOLANT TEMPERATURE SENSORÐ
PCM INPUT........................... 36
FUEL INJECTORSÐPCM OUTPUT.......... 44
FUEL PUMP RELAYÐPCM OUTPUT......... 42
GENERATOR FIELDÐPCM OUTPUT......... 42
HEATED OXYGEN SENSOR (O2S SENSOR)Ð
PCM INPUT........................... 37
IDLE AIR CONTROL MOTORÐPCM OUTPUT . . 42
IGNITION COILÐPCM OUTPUT............. 45
INTAKE AIR TEMPERATURE SENSORÐPCM
INPUT (2.4L ONLY)..................... 41
KNOCK SENSORÐPCM INPUT............. 38
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPÐPCM OUTPUT.................. 46
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐPCM INPUT.................. 39
POWERTRAIN CONTROL MODULE (PCM).... 32
PROPORTIONAL PURGE SOLENOID......... 43
SOLID STATE FAN RELAYÐPCM OUTPUT.... 46
SPEED CONTROL SOLENOIDSÐ
PCM OUTPUT......................... 46
SPEED CONTROLÐPCM INPUT............ 39STARTER RELAYÐPCM OUTPUT........... 42
SYSTEM DIAGNOSIS..................... 32
TACHOMETERÐPCM OUTPUT............. 47
THROTTLE BODY....................... 47
THROTTLE POSITION SENSOR (TPS)Ð
PCM INPUT........................... 40
TORQUE CONVERTER CLUTCH SOLENOIDÐ
PCM OUTPUT......................... 46
TRANSAXLE PARK/NEUTRAL SWITCHÐ
PCM INPUT........................... 40
VEHICLE SPEED AND DISTANCEÐ
PCM INPUT........................... 41
DIAGNOSIS AND TESTING
ASD AND FUEL PUMP RELAYS............. 59
CAMSHAFT AND CRANKSHAFT POSITION
SENSOR............................. 61
ENGINE COOLANT TEMPERATURE SENSOR . . 61
HEATED OXYGEN SENSOR............... 61
KNOCK SENSOR........................ 61
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR............................. 60
THROTTLE BODY MINIMUM AIR FLOW
CHECK PROCEDURE................... 62
THROTTLE POSITION SENSOR............ 62
VISUAL INSPECTIONÐ2.4L ENGINE......... 47
VISUAL INSPECTIONÐ3.0L ENGINE......... 52
VISUAL INSPECTIONÐ3.3/3.8L ENGINES..... 55
REMOVAL AND INSTALLATION
AIR CLEANER ELEMENT.................. 70
AUTOMATIC SHUTDOWN (ASD) RELAY...... 64
CAMSHAFT POSITION SENSOR............ 68
CRANKSHAFT POSITION SENSOR.......... 68
DOWNSTREAM OXYGEN SENSOR.......... 69
ENGINE COOLANT TEMPERATURE
SENSORÐ2.4L........................ 70
ENGINE COOLANT TEMPERATURE
SENSORÐ3.0L........................ 71
ENGINE COOLANT TEMPERATURE
SENSORÐ3.3/3.8L..................... 71
FUEL PUMP RELAY...................... 64
IDLE AIR CONTROL MOTOR............... 65
INTAKE AIR TEMPERATURE SENSORÐ2.4L . . . 72
KNOCK SENSOR........................ 70
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ2.4/3.3/3.8L.................. 66
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ3.0L........................ 66
POWERTRAIN CONTROL MODULE.......... 67
PROPORTIONAL PURGE SOLENOID VALVE . . . 66
NSFUEL SYSTEM 14 - 29

When metal aligns with the sensor, voltage goes
low (less than 0.5 volts). When a notch aligns with
the sensor, voltage spikes 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 events.
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 associated
with the particular cylinder. The arrows and cylinder
call outs on Figure 4 represent which cylinder the
flat spot and notches identify, they do not indicate
TDC position.The camshaft position sensor is mounted to the top
of the timing case cover (Fig. 4). The bottom of the
sensor is positioned above the camshaft sprocket.
The distance between the bottom of sensor and
the camshaft sprocket is critical to the opera-
tion of the system. When servicing the camshaft
position sensor, refer to the 3.3L and 3.8L Multi-
Port Fuel InjectionÐService Procedures sec-
tion in this Group.
2.4L
The camshaft position sensor attaches to the rear
of the cylinder head (Fig. 5). A target magnet
attaches to the rear of the camshaft and indexes to
the correct position (Fig. 6). The target magnet has
four different poles arranged in an asymmetrical pat-
tern. As the target magnet rotates, the camshaft
position sensor senses the change in polarity (Fig. 7).
The sensor output switch switches from high (5.0
volts) to low (0.30 volts) as the target magnet rotates.
When the north pole of the target magnet passes
under the sensor, the output switches high. The sen-
sor output switches low when the south pole of the
target magnet passes underneath.
Fig. 2 Camshaft Position Sensor
Fig. 3 Camshaft Sprocket
Fig. 4 Camshaft Position Sensor Location
14 - 34 FUEL SYSTEMNS
DESCRIPTION AND OPERATION (Continued)