Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 206
the coil between the towers of each individual coil (Fig.
4). Secondary resistance should be 7,000 to 15,800
ohms. Replace the coil if resistance is not within
tolerance.
FAILURE TO START TEST
This no-start test checks the camshaft sensor and
crankshaft sensor.
The engine controller supplies 9 volts to the camshaft
sensor and crankshaft sensor through one circuit. If
the 9-volt supply circuit is shorted to ground, neither
sensor will produce a signal (output voltage to the
engine controller).
When the ignition key is turned and left in the On
position, the engine controller automatically energizes
the auto shutdown (ASD) relay. However, the controller
de-energizes the relay within one second because it has
not received a crankshaft signal indicating engine
rotation.
During cranking, the ASD relay will not energize
until the engine controller receives a crankshaft signal.
Secondly, the ASD relay remains energized only if the
controller senses a camshaft sensor signal immediately
after detecting the crankshaft sensor signal.
(1) Check battery voltage. Voltage should approxi-
mately 12.66 volts or higher to perform failure to start
test.
(2) Disconnect the harness connector from the coil
pack (Fig. 2).
(3) Connect a test light to the B+ (battery voltage)
terminal of the coil electrical connector and ground.
The wire for the B+ terminal is dark green with a black
tracer.
(4) Turn the ignition key to the ON position. The
test light should flash On and then Off. Do not turn
the Key to off position, leave it in the On position.
(a) If the test light flashes momentarily, the engine
controller grounded the auto shutdown (ASD) relay.
Proceed to step 5.
(b) If the test light did not flash, the ASD relay did
not energize. The cause is either the relay or one of
the relay circuits. Use the DRB II to test the ASD
relay and circuits. Refer to the appropriate Power-
train Diagnostics Procedure Manual. Refer to the
wiring diagrams section for circuit information.
(5) Crank the engine. (If the key was placed in the
off position after step 4, place the key in the On
position before cranking. Wait for the test light to flash
once, then crank the engine.)
(a) If the test light momentarily flashes during
cranking, the engine controller is not receiving a
camshaft sensor signal. Use the DRB II to test the
camshaft sensor and sensor circuits. Refer to the
appropriate
Powertrain
Diagnostics
Procedure
Manual. Refer to the wiring diagrams section for
circuit information.
(b) If the test light did not flash during cranking,
unplug the camshaft sensor connector. Turn the
ignition key to the off position. Turn the key to the
On position, wait for the test light to momentarily
flash once, then crank the engine. If the test light
momentarily flashes, the camshaft sensor is shorted
and must be replaced. If the light did not flash, the
cause of the no-start is in either the crankshaft
sensor/camshaft sensor 9-volt supply circuit, or the
crankshaft sensor 5-volt output or ground circuits.
Use the DRB II to test the crankshaft sensor and the
sensor circuits. Refer to the appropriate Powertrain
Diagnostics Procedure Manual. Refer to the wiring
diagrams section for circuit information.
COOLANT TEMPERATURE SENSOR TEST
(1) With key off, disconnect wire connector from
coolant temperature sensor (Fig. 5).
(2) Connect one lead of ohmmeter to one terminal of
coolant temperature sensor.
Fig. 4 Checking Ignition Coil Secondary Resistance
Fig. 5 Coolant Temperature Sensor Test
.
IGNITION SYSTEMS
8D - 33
(3) Connect the other lead of ohmmeter to remaining
connector of coolant temperature sensor. The ohmme-
ter should read as follows;
• Engine/Sensor hot at normal operating temperature
around 200°F should read approximately 700 to 1,000
ohms.
• Engine/Sensor at room temperature around 70°F,
ohmmeter should read approximately 7,000 to 13,000
ohms.
See On Board Diagnostics in the General Diag-
nosis section of Group 14, or refer to the appro-
priate diagnostic manual for further test proce-
dures.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
TEST
Refer to the appropriate Powertrain Diagnostic Pro-
cedure manual.
CRANKSHAFT SENSOR AND CAMSHAFT SENSOR
TESTS
Refer to the appropriate Powertrain Diagnositc Pro-
cedure manual.
8D - 34
IGNITION SYSTEMS
.
3.3L IGNITION SYSTEMS—SERVICE PROCEDURES
INDEX
page
page
Camshaft Sensor
. . . . . . . . . . . . . . . . . . . . . . . . . 38
Coolant Temperature Sensor
. . . . . . . . . . . . . . . . 35
Crankshaft Timing Sensor
. . . . . . . . . . . . . . . . . . 38
Engine Controller
. . . . . . . . . . . . . . . . . . . . . . . . . 35
Idle Rpm Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ignition Coil
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ignition Timing Procedure
. . . . . . . . . . . . . . . . . . . 38
Manifold Absolute Pressure (MAP) Sensor
. . . . . . 39
Spark Plug Cable Service . . . . . . . . . . . . . . . . . . . 36
Spark Plug Service
. . . . . . . . . . . . . . . . . . . . . . . 36
ENGINE CONTROLLER
REMOVAL
(1) Remove air cleaner duct or air cleaner assembly.
(2) Remove battery.
(3) Remove engine controller mounting screws (Fig.
1).
(4) Remove 60-way connector from engine controller.
Remove controller.
INSTALLATION
(1) Connect 60-Way connector to engine controller
(Fig. 1).
(2) Install Engine Controller on inside left front
fender (Fig. 1). Install and tighten mounting screws.
(3) Install the battery.
(4) Install air cleaner duct or air cleaner assembly.
COOLANT TEMPERATURE SENSOR
The coolant temperature sensor is located below the
ignition coil (Fig. 2).
REMOVAL
(1) Drain cooling system until coolant level is below
coolant sensor. Refer to Group 7, Cooling System.
(2) Remove electrical connector from coil (Fig. 3).
Fig. 1 Removing the Engine Controller
Fig. 2 Coolant Temperature Sensor
Fig. 3 Ignition Coil Removal
.
IGNITION SYSTEMS
8D - 35
(3) Remove coil mounting screws.
(4) Rotate coil away from coolant temperature sen-
sor.
(5) Disconnect electrical connector from coolant tem-
perature sensor.
(6) Remove sensor from engine.
INSTALLATION
(1) Tighten the coolant sensor to 7 N
Im (60 in. lbs.)
torque.
(2) Connect electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
(4) Install coil. Tighten coil mounting screws to 12
N
Im (105 in. lbs.) torque.
(5) Connect electrical connector to coil.
SPARK PLUG CABLE SERVICE
Clean high tension cables with a cloth moistened
with a non-flammable solvent. Wipe the cables dry.
Check for brittle or cracked insulation.
When testing cables for punctures and cracks with
an oscilloscope, follow the instructions of the equip-
ment manufacturers.
CAUTION: Do not leave any one spark plug cable
disconnected any longer than necessary during test
or possible heat damage to catalytic converter will
occur. Total test time must not exceed ten minutes.
If an oscilloscope is not available, cables can be tested
as follows:
(1) With the engine not running, connect one end of
a test probe (i.e. a piece of wire with insulated alligator
clips on each end) to a good ground, other end free for
probing.
WARNING: THE 3.3L ENGINE DIRECT IGNITION SYS-
TEM GENERATES APPROXIMATELY 40,000 VOLTS.
PERSONAL INJURY COULD RESULT FROM CON-
TACT WITH THIS SYSTEM.
(2) With engine running, move test probe along
entire length of all cables (approximately 0 to 1/8 inch
gap). If punctures or cracks are present there will be a
noticeable spark jump from the faulty area to the
probe. Cracked, leaking or faulty cables should be
replaced.
Use the following procedure when removing the high
tension cable from the spark plug. First, remove the
cable from the retaining bracket. Then grasp the ter-
minal as close as possible to the spark plug. Rotate the
cover (boot) slightly and pull straight back. Do not use
pliers and do not pull the cable at an angle. Doing
so will damage the insulation, cable terminal or the
spark plug insulator. Wipe spark plug insulator
clean before reinstalling cable and cover.
Resistance cables are identified by the words Elec-
tronic Suppression.
Use an ohmmeter to check cables for opens, loose
terminals or high resistance.
(a) Remove cable from spark plug.
(b) Remove cable from the coil tower.
(c) Connect the ohmmeter between spark plug end
terminal and the coil end terminal. Resistance
should be within tolerance shown in the cable resis-
tance chart. If resistance is not within tolerance,
replace cable assembly. Test all spark plug cables in
same manner.
SPARK PLUG SERVICE
When replacing the spark plug cables, route the
cables correctly and secure them in the appropriate
retainers. Failure to route the cables properly can
cause the radio to reproduce ignition noise, cross igni-
tion of the spark plugs or short circuit the cables to
ground.
SPARK PLUG REMOVAL
Always remove the spark plug cable by grasping at
the spark plug boot, turning 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 rubber or foam insert.
(3) Inspect the spark plug condition. Refer to Spark
Plug Condition in this section.
SPARK PLUG GAP ADJUSTMENT
(1) Check the spark plug gap with a gap gauge. If the
gap is not correct, adjust it by bending the ground
electrode (Fig. 4).
SPARK PLUG INSTALLATION
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 N
Im (20 ft. lbs.)
torque.
(3) Install spark plug cables over spark plugs.
IDLE RPM TEST
WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
ANY ENGINE RUNNING TESTS.
CABLE RESISTANCE CHART
8D - 36
IGNITION SYSTEMS
.
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