Chrysler Town, Dodge Caravan. Manual — part 1086
(10) Remove the Air Cleaner Box (Fig. 7).
(11) Remove the 2 lower mounting Bolts (Fig. 8).
(12) Remove generator.
INSTALLATION - 2.5L
(1) Install generator.
(2) Install the 2 lower mounting Bolts (Fig. 8).
(3) Install the Air Cleaner Box (Fig. 7).
(4) Install the upper support bracket (Fig. 6).
(5) Install the wiring harness on upper generator
bracket (Fig. 6).
(6) Connect the field connection (Fig. 5).
(7) Connect the generator battery connection (Fig.
5).
(8) Raise vehicle and support.
(9) Install the generator drive belt (Fig. 4).
(10) Install the right front splash shield (Fig. 3).
(11) Lower vehicle.
(12) Install the engine cover (Fig. 2).
(13) Connect the negative battery cable (Fig. 1).
Fig. 7 AIR BOX REMOVED
Fig. 8 GENERATOR LOWER BOLTS
1 - Lower Mounting Bolts
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CHARGING
8F - 3
GENERATOR (Continued)
STARTING
TABLE OF CONTENTS
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STARTER MOTOR
. . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 4
STARTER MOTOR
REMOVAL - 2.5L
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) Remove the lower engine splash shield.
(4) Remove the electrical connectors from the
starter (Fig. 1).
(5) Remove the starter mounting bolts (Fig. 2).
(6) Remove the starter.
INSTALLATION - 2.5L
(1) Raise vehicle and support.
(2) Install the starter.
(3) Install the starter mounting bolts (Fig. 2).
(4) Install the electrical connectors to the starter
(Fig. 1).
(5) Install the lower engine splash shield.
(6) Connect the negative battery cable.
(7) Lower vehicle.
Fig. 1 STARTER LOCATION
Fig. 2 STARTER MOUNTING BOLTS
1 - Starter
2 - Mounting Bolts
8F - 4
STARTING
RG
IGNITION CONTROL
TABLE OF CONTENTS
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GLOW PLUG
. . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GLOW PLUG RELAY
. . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CAMSHAFT POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . 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 “ON” 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
RG
IGNITION CONTROL
8I - 1
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
9
Key ON
9
Wait-To
Start Lamp
9
ON
9
(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
electronic 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
8I - 2
IGNITION CONTROL
RG
GLOW PLUG RELAY (Continued)
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