Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 207
Engine idle set rpm should be tested and recorded
as it is when the vehicle is first brought into shop
for testing. This will assist in diagnosing complaints
of engine stalling, creeping and hard shifting on ve-
hicles equipped with automatic transmissions.
Proceed to the Throttle Body Minimum Airflow pro-
cedures.
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
(1) Warm engine in Park or Neutral until the cooling
fan has cycled on and off at least once.
(2) Ensure that all accessories are off.
(3) Shut off engine.
(4) Disconnect the PCV valve hose from the intake
manifold nipple.
(5) Attach Air Metering Fitting #6457 (0.125 in.
orifice) to the intake manifold PCV nipple (Fig. 5).
(6) Disconnect the 3/16 inch idle purge line from the
throttle body nipple (Fig. 6). Cap the 3/16 inch nipple.
(7) Connect Diagnostic Readout Box II (DRB II).
(8) Restart the engine. Allow engine to idle for at
least one minute.
(9) Using the DRBII, access Min. Airflow Idle Spd.
(10) The following will then occur:
• AIS motor will fully close.
• Idle spark advance will become fixed.
• Engine RPM will be displayed on DRB II.
(11) If idle RPM is within the range shown in the
Idle Specification chart, throttle body minimum air-
flow is set correctly.
(12) If idle RPM is not within specifications, shut off
the engine and clean the throttle body as follows:
(a) Remove the throttle body from engine.
WARNING: CLEAN THROTTLE BODY IN A WELL
VENTILATED AREA. WEAR RUBBER OF BUTYL
GLOVES, DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
(b) While holding the throttle open, spray the
entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only use
Mopar Parts Cleaner to clean the throttle body.
(c) Using a soft scuff pad, clean the top and bottom
of throttle body bore and the edges and manifold side
of the throttle blade. The edges of the throttle
blade and portions of the throttle bore that are
closest to the throttle blade when is closed,
must be free of deposits.
(d) Use compressed air to dry the throttle body.
(e) Inspect throttle body for foreign material.
(f) Install throttle body on manifold.
(g) Repeat steps 1 through 14. If the minimum air
flow is still not within specifications, the problem is
not caused by the throttle body.
(13) Shut off engine.
(14) Remove Air Metering Fitting #6457 from the
intake manifold PCV nipple. Reinstall the PCV valve
hose.
Fig. 4 Setting Spark Plug Gap—Typical
Fig. 5 Air Metering Fitting #6457
IDLE SPECIFICATIONS
.
IGNITION SYSTEMS
8D - 37
(15) Uncap the throttle body idle purge nipple and
connect the idle purge line.
(16) Remove DRB II.
IGNITION TIMING PROCEDURE
The 3.3L engine uses a fixed ignition system. Basic
ignition timing is not adjustable. The engine controller
regulates ignition timing.
CRANKSHAFT TIMING SENSOR
REMOVAL
(1) Disconnect crankshaft timing sensor electrical
connector from the wiring harness connector (Fig. 6).
(2) Remove crankshaft timing sensor retaining bolt.
(3) Pull crankshaft timing sensor straight up out of
the transaxle housing.
INSTALLATION
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 re-
placed, confirm that the paper spacer is attached
to the face of the new sensor (Fig. 7).
(1) Install sensor in transaxle and push sensor down
until contact is made with the drive plate. While
holding the sensor in this position, install and tighten
the retaining bolt to 11.9 N
Im (105 in. lbs.) torque.
(2) Connect crankshaft timing sensor electrical con-
nector to the wiring harness connector.
CAMSHAFT SENSOR
REMOVAL
(1) Disconnect camshaft reference sensor electrical
connector from the wiring harness connector (Fig. 8).
(2) Loosen camshaft timing sensor retaining bolt
enough to allow slot in sensor to slide past the bolt.
(3) Pull sensor up out of the chain case cover. Do not
pull on the sensor lead. There is an O-ring on the
sensor case. The O-ring may make removal difficult. A
light tap to top of sensor prior to removal may reduce
force needed for removal.
INSTALLATION
If the removed sensor is reinstalled, clean off
the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation.
Inspect O-ring for damage, replace if necessary. If the
sensor is being replaced, confirm that the paper spacer
is attached to the face and O-ring is positioned in
groove of the new sensor (Fig. 9).
Fig. 6 Crankshaft Timing Sensor
Fig. 7 Crankshaft Sensor and Spacer
Fig. 8 Camshaft Sensor
Fig. 9 Camshaft Sensor
8D - 38
IGNITION SYSTEMS
.
(1) Apply a couple drops of clean engine oil to the
O-ring prior to installation. Install sensor in the chain
case cover and push sensor down until contact is made
with the cam timing gear. While holding the sensor in
this position, install and tighten the retaining bolt 11.9
N
Im (105 in. lbs.) torque.
(2) Connect camshaft reference sensor electrical con-
nector to harness connector. Position connector away
from the accessory belt.
IGNITION COIL
(1) Remove spark plug cables from coil (Fig. 10).
(2) Remove ignition coil electrical connector.
(3) Remove ignition coil mounting screws.
(4) Remove ignition coil.
Reverse the above procedure for installation. Tighten
mounting screws to 12 N
Im (105 in. lbs.) torque.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
(1) Disconnect electrical connector from MAP sensor.
(2) Remove sensor by unscrewing from the intake
manifold (Fig. 11).
(3) Reverse the above procedure for installation.
Fig. 11 Manifold Absolute Pressure Sensor
Fig. 10 Ignition Coil Removal and Installation
.
IGNITION SYSTEMS
8D - 39
IGNITION SWITCH
IGNITION SWITCH AND KEY CYLINDER SERVICE
The ignition switch is located on the steering column.
The Key In Switch is located in the ignition switch
module. For diagnosis of the Key In Switch, refer to
Section 8M.
REMOVAL
(1) Disconnect negative cable from battery.
(2) If the vehicle has a tilt column, remove the tilt
lever by turning it counterclockwise.
(3) Remove upper and lower covers from steering
column.
(4) Remove ignition switch mounting screws. Use
tamper proof torx bit Snap-on TTXR15A2, TTXR20A2
or equivalent to remove the screws (Fig. 1).
(5) Gently pull switch away from the column. Re-
lease connector locks on the 7 terminal wiring connec-
tor, then remove the connector from the ignition
switch.
(6) Release connector lock on the 4 terminal connec-
tor, then remove the connector from the ignition
switch.
(7) To remove the key cylinder from the ignition
switch:
(a) Insert key in the ignition switch. Turn the key
to the LOCK position. Using a small screwdriver,
depress the key cylinder retaining pin until it is flush
with the key cylinder surface (Fig. 2).
(b) Rotate the key clockwise to the OFF position.
The key cylinder will unseat from the ignition switch
(Fig. 3). When the key cylinder is unseated, it will be
approximately 1/8 inch away from the ignition switch
halo light ring. Do not attempt to remove the key
cylinder at this time.
(c) With the key cylinder in the unseated position,
rotate the key counterclockwise to the lock position
and remove the key.
(d) Remove key cylinder from ignition switch (Fig.
4).
Fig. 1 Ignition Switch Screw Removal
Fig. 2 Key Cylinder Retaining Pin
IGNITION SWITCH DESIGNATIONS
8D - 40
IGNITION SYSTEMS
.
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