08D Ignition System

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IGNI IG NIT TIO ION N SY SYST STE EM

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IGNITION SYSTEM TABLE TA BLE OF CONTENT S page

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DESCRIPTION AND OPERATION IGNITION SYSTEM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 1 DISTRIBUTO DISTR IBUTOR— R— 5.2L/5.9L V-8 ENG NGINE. INE. . . . . . . . 1 SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . . 2 IGNITION COIL (EXC (EXCE EPT 4.7L ENGINE NGINE). ). . . . . . . . 2 IGNITION COIL— COIL— 4.7L ENGINE NGINE.. . . . . . . . . . . . . . . 3 CRANKSHAF CRA NKSHAFT T POS POSITION ITION SE SENSOR— NSOR— 5.2/5.9L V-8 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CRANKSHAF CRA NKSHAFT T POS POSITION ITION SE SENSOR— NSOR— 4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CAM CA M SHAF SHAFT T POS POSITION ITION SE SENSOR. NSOR. . . . . . . . . . . . . . 4 CAM CA M SHAF SHAFT T POS POSITION ITION SENSOR— SENSOR— 4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IGNITION SWITCH AND KEY LOCK CYLINDER CY LINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DIAGNOSIS AND TESTING DISTRIBUTOR CAP. . . . . . . . . . . . . . . . . . . . . . . . 6 DISTRIBUTOR DISTRIBUTO R ROT ROTOR OR . . . . . . . . . . . . . . . . . . . . . 6 SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . . 7 SPARK SPA RK PLUG CONDITIONS CONDITIONS . . . . . . . . . . . . . . . . . 8 IGNITION SWITCH AND KEY LOCK CYLINDER CY LINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL AND INSTALLATION SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . 11

SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 11 IGNITION IGNITIO N CO COIL— IL— 3.9/5.2/ 5.9L ENGINE NGINES S . . . . . . 12 IGNITION IGNITIO N CO COIL— IL— 4.7L ENGINE NGINE.. . . . . . . . . . . . . . 13 CRANKSHAF CRA NKSHAFT T POSIT POSITION ION SE SENSOR— NSOR— 3.9/5.2/ 5.9L ENGINE NGINES S . . . . . . . . . . . . . . . . . . . . . . . . . 14 CRANKSHAF CRA NKSHAFT T POSITION SENSOR— SENSOR— 4.7L V-8 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 CAM CA M SHAF SHAFT T POS POSITION ITION SE SENSOR. NSOR. . . . . . . . . . . . . 15 CAM CA M SHAF SHAFT T POS POSITION ITION SE SENSOR— NSOR— 4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DISTRIBUT DIST RIBUTOR ORS— S— 3.9/5.2/5.9L ENG NGINE INES S . . . . . . 16 IGNITION SWITCH AND KEY CYLINDER . . . . . . 17 COLUMN SHIFT INTERLOCK . . . . . . . . . . . . . . . 21 SPECIFICATIONS IGNITIO IGN ITION N TIMING. . . . . . . . . . . . . . . . . . . . . . . . 21 ENGINE FIRING FIRING ORDER— ORDER— 5.2L/5.9L V-8 ENGINE NGINES S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ENGINE FIRING FIRING ORDE ORDER— R— 4.7L V-8 ENGINE . . . 21 SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SPARK SPA RK PLUG CABLE RESISTANC RESISTANCE E . . . . . . . . . . 22 IGNITION CO COIL IL RESIST RESISTANCE ANCE— — EXC EXCEPT EPT 4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 IGNITION IGNITIO N CO COIL IL RE RESIST SISTANCE ANCE— — 4.7L V-8 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 TORQUE TO RQUE CHART CHART . . . . . . . . . . . . . . . . . . . . . . . . . 22

DESCRIPTION AND OPERATION

Ignit io ion n Coi Coil( l(s) s) Secondary ondary Ignitio Ignition n Cables (5.2L 5.2L/5 /5.9L .9L en gines) • Sec • Distributor (contains rotor and camshaft position sensor) (5.2L/5.9L engines) • Powertrain Control Module (PCM) • Crankshaft Position and Camshaft Position Sensors • The MAP, TPS, IAC and ECT also have an effect on the control of the ignition system.

IGNITION SYSTEM DESCRIPTION Two diff different ig ignitio nition n syste systems ms are used. One type of system is for the 5.2L/5.9L V-8 engine. The other is forr the 4.7L V-8 fo V-8 engine. The ignition systems used on 5.2L/5.9L V-8 engines are basic basicall ally y ide identic ntical al using a conventio nventional nal distri distribubutor and remo remotely tely mounted coil il.. The 4.7 4.7L L V-8 engi engine ne does not use a distributor and has 8 separate coils.

OPERATION The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. The ignition system consists of: gs • S p a r k P l u gs

•

DISTRIBUTO DISTRIB UTOR— R— 5. 2L/5. 9L V-8 V-8 ENGINE ENGINE DESCRIPTION The 5.2L 5.2L/5 /5.9L .9L V-8 V-8 engine is equipped with a camshaft driv driven en mec mechan han ic ical al dis distributor tributor (Fig. 1) containcontaining a shaft driv driven en dis distributor tributor roto rotor. r. All All distributors distributors are equi equipped pped with an internal camsha ft po positi sitio on (fuel sync) sensor (Fig. 1).

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IGNI IG NIT TIO ION N SYS SYST TEM

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DESCRIPTION DESC RIPTION AND OPERATION OPERATION (Con (Continued) tinued) gle plug displaying gle displaying an abnormal conditio ndition n indi indiccates that a prob proble lem m exi exists sts in the correspo rresponding nding cylinder cylinder.. Replace Repl ace spark plug plugss at the interval intervalss r ec eco ommended in Group O, Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defec defectiv tive, e, carbon carbon or oil fouled. Also refer to Spark Plug Conditions.

CAUTION: Never use a motorized wire wheel brush CAUTION: to cl clea ean n th the e sp spar ark k pl plug ugs. s. Me Meta tall llic ic de depo posi sits ts wi will ll remain rem ain on the spark plug ins insula ulator tor and will cause plug misfire.

SPARK PLUG CABLES Fig. 1 Distributor and Camshaft Position Sensor 1 2 3 4

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SYNC SIGNAL SIGNAL GENE GENERA RATOR TOR CAMSHAFT CAMS HAFT POSITIO POSITION N SENSOR SENSOR PULSE PUL SE RING RING DISTRIBUT DISTR IBUTOR OR ASSEMBL ASSEMBLY Y

OPERATION The camsha ft po positi sitio on senso sensorr prov provide idess fuel inj injec ec-tion synchronization and cylinder identification. The distributor distributor do does es n ot have built in centrifugal centrifugal or v a cu cu u m a s s is is t e d a d va va n c e. e. B a s e i gn gn i t io ion t i m in in g a n d a l l t i m in in g a d v a n ce ce i s con t r o ll ll ed ed b y t h e P ow ow er er train Control Module (PCM). Because ignition timing is controlled by the PCM, b a s e i g n i t i o n t i m i n g i s n o t a d ju ju s t a b l e . The distributor is held to the engine in the convent io i on a l m e th t h od od u s in in g a h ol old d ow ow n cla m p a n d b ol olt . Although the distributor can be rotated, it will have no effect on ignition timing. Al l d i st st r i bu bu t o r s con t a i n a n i n t er er n a l oi l s e a l t h a t p r e ve ve n t s oi l fr om om e n t e r in in g t h e d is is t r ib ib u t or or h ou ou s in in g . The seal is not serviceable.

SPARK SPA RK PLUGS DESCRIPTION All engines use resistor type spark plugs. 4.7L V-8 engines engi nes are equi equipped pped with “fired in suppresso suppressorr seal” t y pe pe s p a r k p lu lu g s u s in in g a cop p er er cor e g r ou ou n d e le le cctrode. Because of the use of an aluminum cylinder head on the 4.7L engine, spark plug torque is very critical. To pr event possi possible ble pr ee-ignitio ignition n an d/o d/orr mechanical engine engi ne damage, th e correct t ype ype//heat range/ range/number number spark plug must be used.

OPERATION R em em ov ove t h e s pa p a r k p lu lu g s a n d e xa xa m in in e t h e m for burned electrodes and fouled, cracked or broken porce la la i n i n su su l a t or or s . K ee ee p p lu lu g s a r r a n g e d i n t h e or d e r in which they were removed from the engine. A sin-

DESCRIPTION Spark plug cable cabless are so sometimes metimes referred referred t o as sec sec-ondary ignition wires.

OPERATION T h e s p a r k p lu lu g ca b le le s t r a n s fe fe r e le le ct ct r i ca ca l cu r r e n t from th e igniti from ignition on coi oil( l(s) s) a nd/o nd/orr distributor, to indivi individdual spark plugs at each cylinder. The resistive spark p lu lu g ca b le le s a r e of n on on m e t a l li li c con s t r u ct ct i on on . T h e cable abless prov provide ide suppressi suppressio on of radio frequenc requency y emis emis-sions from the ignition system.

IGNITION COIL (EXCEPT 4.7L ENGINE) DESCRIPTION A single single fil ille led. d. The com p ou ou n d . t a n ce ce t h a t engine.

ignitio ig nition n coil is used. The coil is not oil coil windings windings are embed embedded ded in an epo epoxy xy T h is is p r ov ov id id e s h e a t a n d v ib ib r a t io ion r e s is is a ll l low s t h e coil t o b e m ou ou n t ed ed on t h e

OPERATION The Pow Powertrain ertrain Co Control ntrol Module Module (PCM) opens opens and closes the ignition coil ground circuit for ignition coil operation. Battery voltage is supplied to the ignition coil positive terminal from the ASD relay. If the PCM does n ot ot s e e a s ig ig n a l fr fr om om t h e cr a n k s h a ft ft a n d ca m s h a ft ft s e n so sor s (i n di di ca ca t i n g t h e i gn gn i t io ion k e y i s O N b u t t h e engine is not running), it will shut down the ASD circuit. Base ignition timing is not adjustable on any ntrolling ing the coil ground circ ircuit, uit, the e n g i n e . By controll PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions.

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DESCRIPTION DESC RIPTION AND OPERATION OPERATION (Con (Continued) tinued)

IGNITION IGNITIO N COIL— COIL— 4. 7L ENGINE ENGINE DESCRIPTION The 4.7L V–8 engine uses 8 dedicated, and individually fired coil (Fig. 2) for each spark plug. Each coil is m ou ou n t e d d ir ir e ct ct ly l y t o t h e t op op of e a ch ch s pa p a r k p lu lu g (Fig. 3).

Fig. 3 Ignition Coil Location—4.7L Engine 1 – IGN IGNITIO ITION N COIL COIL 2 – COIL ELECTR ELECTRICAL ICAL CONNEC CONNECTOR TOR 3 – COIL M MOUNTI OUNTING NG STUD/NUT STUD/NUT

Fig. 2 Ignition Coil—4.7L Engine 1 – OO-RI RING NG 2 – IGNITI IGNITION ON COIL COIL 3 – ELEC ELECTRICA TRICAL L CONNECT CONNECTOR OR

OPERATION

Battery vo voltage ltage is suppli supplied ed to t he 8 ig ignitio nition n coil ilss from the ASD relay. The Powertrain Control Module (PCM) opens and closes each ignition coil ground circuit at a determined time for ignition coil operation. B a s e i g n i t i o n t i m i n g i s n o t a d j u s t a b l e . By controlling the coil ground circuit, the PCM is able to set t h e b as a s e t im im in in g a n d a d ju ju s t t h e ign it i t io ion t im im in in g advance. This is done to meet changing engine operating conditions. The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine. Becau Bec au se of co coil design, sp ark plug cabl cables es (se (seco condndary cables) are not used.

Engine speed and crankshaft position are provided thr ough the CKP sensor. sensor. The senso sensorr gene generates rates pulse pulsess t h a t a r e t h e in p u t s en en t t o t h e P ow ow er er t r a in in C on on t r ol ol Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On 5.2/ 5.2/5.9L 5.9L V-8 V-8 engines, the flyw lywheel/ heel/drive drive plate has 8 single notches, spaced every 45 degrees, at its outer edge (Fig. 4). T h e n ot ch ch e s ca u s e a p u ls ls e t o b e g en en e r a t e d w h e n t h e y p a s s u n d e r t h e s e n so sor . T h e p u ls ls e s a r e t h e i n pu pu t t o t h e P C M . F or or e a ch ch e n gi gi n e r e v ol ol u t io ion , t h e r e a r e 8 pulses generated on V-8 engines. T h e e n gi gi n e w i ll ll n ot ot op e r a t e i f t h e P C M d o es es n ot ot receive a CKP sensor input.

CRA RANK NKSHA SHAFT FT PO POSITIO SITION N SE SENSO NSOR— R— 5. 2/5. 9L V-8 ENGINE

CRANKSHAFT CRANKSHA FT POSITION SENSOR— SENSOR— 4. 7L ENGINE

DESCRIPTION

DESCRIPTION

The Cranksha ft Posi Positio tion n (CKP) sensor sensor is located located near the outer edge of the flywheel (starter ringear).

The Crankshaft Position Sensor (CKP) is mounted into th e rightright-rear rear side of the engi engine ne bl blo ock (Fig Fig.. 5) 5)..

OPERATION

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DESCRIPTION DESC RIPTION AND OPERATION OPERATION (Con (Continued) tinued)

OPERATION Engine speed and crankshaft position are provided t h r o u gh gh t h e cr a n k s h a ft ft p os os it it i on on s en en s or or . T h e s en en s or or generates pulses that are the input sent to the powe r t r a i n con t r o l m od u le le (P C M ). ). T h e P C M i n t er er p r e t s t h e s e n so sor i n p u t t o d e t e r m in in e t h e cr a n k s h a ft ft p os os iit i on on . T h e P C M t h e n u s e s t h i s p o si si t io ion , a l on on g w it it h other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On the 4.7 4.7L L V–8 engine, engine, a tonew tonewheel heel is bolted bolted to t h e e n gi gi n e cr a n k s h a f t (F i g. g. 6 ). ). T h is is t on on e w h ee ee l h a s sets of notches at its outer edge (Fig. 6). T h e n ot ch ch e s ca u s e a p u ls ls e t o b e g en en e r a t e d w h e n t h e y p a s s u n d e r t h e s e n so sor . T h e p u ls ls e s a r e t h e i n pu pu t to the PCM.

Fig. 4 CKP Sensor Operation—5.2L/5.9L Engine 1 – CRAN CRANKSHA KSHAFT FT POSITION POSITION SENSOR SENSOR 2 – NOTCHE NOTCHES S 3 – FL FLYWHE YWHEEL EL

Fig. 6 CKP Sensor Operation and Tonewheel—4.7L V–8 Engine 1 2 3 4

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TONEWHEE TONEWH EEL L NOTCH NOT CHES ES CRANKSHA CRAN KSHAFT FT POSITION POSITION SENSOR SENSOR CRANKSHA CRAN KSHAFT FT

CAMSHAFT POSITION SENSOR Fig. 5 CKP Sensor Location—4.7L V–8 Engine 1 – CRAN CRANKSHA KSHAFT FT POSITION POSITION SENSOR SENSOR 2 – MOUNTING MOUNTING BOL BOLT T

DESCRIPTION The Camshaft Posi Positio tion n (CMP) sensor sensor is loc located in the distri distributor butor..

OPERATION The senso sensorr conta ins a hall ef efffec ectt dev devic icee call alled ed a sync signal generator to generate a fuel sync signal.

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DESCRIPTION DESC RIPTION AND OPERATION OPERATION (Con (Continued) tinued) T h is is s yn yn c s ig ig n a l g en en e r a t or or d e t ec ect s a r ot ot a t i n g p u ls ls e ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees degrees t hrough th e sync signal signal gene generarator. Its signal is used in conjunction with the Cranksha ft Position Position (C (CKP) KP) sensor to different different iate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves th e syn c signal genera tor, the fol ollo lowing wing occ occur s: The change of th e m agnetic fie field ld causes t he sync sigsignal vo voltage ltage to swi switch tch lo low w to 0 vo volts. lts.

located on a tonew loc tonewheel heel.. The tonew tonewheel heel is lo loccated at the front of the camshaft for the right cylinder head (Fig. 8). As the tonewheel rotates, the notches pass through the sync signal generator. The pattern of the n ot ot ch ch e s (v ie ie we we d cou n t e r -c -cl oc ock w is is e fr om om fr on on t of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches 1 notch, 3 notches and 1 notch. The signal from the CMP sensor is used in conjunction with the cran kshaft po positi sitio on senso sensorr to dif diffferentiate betwe between en fuel injec injectio tion n and spark ev events. ents. It is also used to synchronize the fuel injectors with their respective cylinders.

CAM CA M SHAF SHAFT T POSITION SENSOR— SENSOR— 4. 7L ENGINE ENGINE DESCRIPTION The Camshaft Posi Positio tion n Senso Sensorr (CMP) on on the 4. 4.7L 7L V–8 engine is bolted to the front/top of the right cylinder head (Fig. 7).

Fig. 8 CMP Sensor and Tonewheel—4.7L Engine 1 2 3 4

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NOTCHES NOTCH ES RIGHT CYLIN CYLINDER DER HEAD HEAD CAMSHAFT CAMS HAFT POSITION POSITION SENSO SENSOR R TONEWH TON EWHEE EEL L

IGNITION SWITCH AND KEY LOCK CYLINDER DESCRIPTION

Fig. 7 CMP Location—4.7L Engine 1 2 3 4

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RIGHT CYLI CYLINDER NDER HEAD HEAD CAMSHAFT CAMS HAFT POSITIO POSITION N SENSOR SENSOR MOUNTING MOUNT ING BOL BOLT T ELEC.. CONNECT ELEC CONNECTOR OR

OPERATION The CMP sensor contains a hall effect device called a s yn yn c s i gn gn a l g en en e r a t or or t o g e n er er a t e a fu e l s y n c s ig ig n a l. l . T h is is s yn yn c s ig ig n a l g en en e r a to t or d et et e ct ct s n ot ot ch ch e s

T h e e le le ct ct r i ca ca l i gn gn i t io ion s w it it ch ch i s l oc oca t e d on t h e steering column. It is used as the main on/off switchi n g d ev evice for m os os t e le le ct ct r ic i ca l com p on on e n t s. s. T h e mechanical key lock cylinder is used to engage/disengage the electrical ignition switch.

OPERATION Ve h i c le l e s e q u i pp p p e d w i t h a n a u t o m at at i c t r a n s le i s m i s s i o n a n d a f l o o r m o u n t e d s h i f t e r : a ca b le used to connect connect t he interlo interlocck dev devic icee in the steeri steering ng col u m n a s s em em b ly ly, t o t h e t r a n s m i s si si on on fl oo oor s h i ft ft lever. This interlock device is used to lock the transmissio missi on shif shifter ter in the PA PARK RK positio position n when the key

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DESCRIPTION DESC RIPTION AND OPERATION OPERATION (Con (Continued) tinued) lock cyl loc ylinder inder is r otated to t he LOCK LOCKED ED or ACCESACCESSORY position. The interlock device within the steering column column is n ot servi servicceabl eable. e. If repair is nec necessary essary,, t h e s t ee ee r in in g colu m n a s se s e m bl bly m u s t b e r e pl pl ac a ce d. d. Refer to Group 19, Steering for procedures. If the ig ignitio nition n key is dif difffic icult ult to r otate to or from t h e L OC OC K or AC CE CE S S O RY RY p o si si t io ion , i t m a y n ot ot b e the fault of the key cyli cylinder nder or the steeri steering ng column column compo mponents. nents. The brake tran smissi smissio on shif shiftt interlo interlocck ca bl b le m a y b e ou t of a d ju ju s tm t m en e n t . R ef efe r t o B ra ra k e Tr a n s m i ss ss io ion S h i ft ft I n t e r lo lock C a b le le Ad ju ju s t m e n t i n Group 21, Transmissions for adjustment procedures. Ve h i c le le s e q u i p pe p e d w i t h a n a u t o m a ti ti c t ra ra n s mission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmissio missi on shif shifter ter in t he PA PARK RK positio position n when the key l oc ock cy li li n de de r i s i n t h e L OC OC K E D or AC CE CE S S O RY RY position. If it is difficult to rotate the key to or from t h e L O CK CK or AC C E SS SS O RY RY p os os it it i on on , t h e i n t er er l oc ock devic dev icee wi within thin the steeri steering ng column may be def defec ectiv tive. e. This device device is not servic serviceable. eable. If repair is n ec ecessary essary,, t h e s t ee ee r in in g colu m n a s se s e m bl bly m u s t b e r e pl pl ac a ce d. d. Refer to Group 19, Steering for procedures. Ve h i c le le s e q u i pp p p e d w i t h a m a n u a l t ra r a n s m i sss io i o n , a f l oo o o r m o u n te t e d s h if i f t e r, r, a n d a L E VE VE R b e l o w t h e i g n i t i o n k e y : A lever lever is lo loccated on the steering column behind the ignition key lock cylinder. The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSOR CCESSORY Y positio position. n. If it is dif difffic icult ult to rotate the key to the LOCK or ACCESSORY position, the lever mechanism may be defective. This mechanism is not servicceabl servi eable. e. If r epair is nec necessary essary,, the steeri steering ng column assembly must be replaced. Refer to Group 19, Steering for procedures. Ve h i c le le s e q u i pp p p e d w i t h a m a n u a l t ra r a n s m i sss i o n , a f l o or o r m o u n t e d s h i ft ft e r, r, a n d N O L E VE VE R b e l o w t h e i g n i t i o n k e y : The igniti ignition on k ey cylinder cylinder m u s t b e d e p r e s s e d t o a l l o w i t t o b e r o t a t e d i n t o t he LOCK or ACCESSOR CCESSORY Y po positi sitio on. If it is dif difffic icult ult to rotate the key to the LOCK or ACCESSORY position, the lock mechanism within the steering column may be def defec ectiv tive. e. This mec mechanism hanism is not servi servicceabl eable. e. If r e p a ir ir i s n e ce ce s sa sa r y, y, t h e s t e er er i n g col u m n a s s em em b ly ly m u s t b e r e p la la ce ce d . R e fe fe r t o G r ou ou p 1 9, 9, S t e er er i n g f or or procedures.

DIAGNOSIS DIAG NOSIS AND TESTING

i n g t h e ca p t h r o u gh gh cr a ck ck s ). ). R ep ep la la ce c e a n y ca p t h a t displays charred or eroded terminals. The machined s u r fa fa ce ce of a t e r m in in a l e n d (fa ce ce s t ow ow a r d r ot ot or or ) w il il l indicate indic ate some evidence evidence of erosio erosion n fro from m normal ope operra t i on on . E x a m in in e t h e t e r m in in a l e n d s for e vi vi de de n ce ce of mechanical interference with the rotor tip.

Fig. 9 Cap Inspection—External—Typical 1 2 3 4

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BROKEN BROKE N TOWER TOWER DISTRIBUT DISTR IBUTOR OR CAP CAP CARBON CARB ON PA PATH CRACK

Fig. 10 Cap Inspection—Internal—Typical 1 – CHAR CHARRED RED OR ERODED ERODED TERMINA TERMINALS LS 2 – WORN OR DAMAGE DAMAGED D ROTOR BUTTO BUTTON N 3 – CARB CARBON ON PA PATH

DISTRIBUTOR CAP

DISTRIBUTOR ROTOR

Remove the distributor cap and wipe it clean with a d r y l in in t fr e e cl ot ot h . Vi su su a l ly ly i n sp sp e ct ct t h e ca p for cr a ck ck s , ca r b on on p a t h s, s , b r ok ok en e n t ow ow er er s or d a m a ge ge d rotor button (Fig. 9) or (Fig. 10). Also check for white deposits on the inside (caused by condensation enter-

Visually inspect th e rotor (Fig. 11) for for cracks, evi evi-d e n ce ce of cor r os os io ion or t h e e ff ffe ct ct s of a r ci ci n g on t h e m e t a l t i p. p. Al so so ch e ck ck for e vi vi de de n ce ce of m e ch ch a n i ca ca l i n t er er fe fe r en en ce ce w it it h t h e ca p . S om om e ch a r r i n g i s n or or m a l

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8D - 7

DIAGNOSIS DIAG NOSIS AND T ESTING (C (Con ontinu tinued) ed) on the end of t he metal tip. The sil silic ico onene-die diele lecctric tric-varnish-ccompo varnishmpound und appli applied ed to t he roto rotorr tip for radio interferenc interf erencee noi noise se suppressi suppressio on, wi will ll a ppear charr ed. This is normal. D o n o t r e m o v e t h e c h a r r e d c o m p o u n d . Te st st t h e s p r in in g for i n su su ff ffi ci ci en en t t e n s io ion . R ep ep la la ce ce a r ot ot or or t h a t d is is p la la y s a n y of t h e s e a d v er er s e conditions.

Fig. 12 Heat Shields—3.9/5.2/5. Shields—3.9/5.2/5.9L 9L Engine Engines s 1 – AIR GAP 2 – SPARK SPARK PLUG PLUG BOOT HEAT HEAT SHIELD SHIELD

TESTING

Fig. 11 Rotor Inspection—Typical 1 2 3 4

– – – –

INSUFFICIENT INSUFFICIE NT SPRING SPRING TENSION TENSION CRAC CR ACKS KS EVIDENCE EVID ENCE OF PHYSICAL PHYSICAL CONT CONTACT ACT WITH CAP ROTOR ROTO R TIP CORR CORRODED ODED

SPARK PLUG CABLES Check the spark plug cable connecti Check connectio ons for go goo od con t a c t a t t h e coi l( l(s ), ), d is is t r i bu bu t or or ca p t ow ow er er s , a n d s p a r k p lu lu g s . T er er m i n a ls ls s h ou ou l d b e fu l ly ly s ea ea t e d . T h e insulators should be in good condition and should fit tightly tig htly on the coil il,, distributor distributor and spark plug plugs. s. Spark plug cables with insulators that are cracked or torn must be replaced. C le le a n h i gh gh v ol ol t a ge ge i gn gn i t io ion ca b le le s w it it h a cl ot ot h moistened moi stened wi with th a nonnon-fflammable solve solvent. nt. Wipe th e cables dry. Check for brittle or cracked insulation. On 3. 3.9L 9L V-6 and 5.2 5.2//5. 5.9L 9L V-8 engi engines, nes, spark plug cable heat shields are pressed into the cylinder head t o s u r r ou ou n d e a ch ch s p a rk r k p lu lu g ca b le le b oo oot a n d s pa pa r k plug (Fig. (Fig. 12). 12). These shiel shields ds pro protec tectt the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be r em e m ov ove d. d. Aft er e r t h e s pa p a r k p lu lu g ca bl b le h a s b ee ee n in s t a ll lle d, d, t h e lip of t h e ca b le le b oo oot s h ou ou ld l d h a ve ve a small air gap to the top of the heat shield (Fig. 12).

When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an osc oscill illosc oscope ope is n ot a vailabl vailable, e, spa rk plug cables may be tested as follows:

CAUTION CAUTI ON:: Do no nott lea leave ve an any y on one e sp spar ark k pl plug ug ca cabl ble e disconnected for longer than necessary during testing. This may cause possible possible heat dam damage age to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are i n g oo ood con d it it i on on , t h e e n gi gi n e r p m s h ou ou l d d r op op a n d t h e e n gi gi n e w il il l r u n p oo oor l y. y. I f e n g in in e r p m d oe oe s n ot ot drop, the cable and/or spark plug may not be operati n g p r op op er er ly l y a n d s h ou ou ld l d b e r e pl pl ac a ce d. d. Als o ch e ck ck engine cy cylinder linder compressio ompression. n. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run t h e ot h er er e nd n d of t h e t es e s t p r ob ob e a lo lon g t h e e nt n t ir ir e length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cable abless sho should uld be r epl eplace aced d with resi resisstance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable ja ck cket et . Use a n ohmmeter to test for open circ ircuits, uits, excesexcess iv ive r e si sis t a n ce ce or loos e t e r mi m i n al a l s. s. I f e qu qu ip i p p ed ed , removee t he dis remov distributor tributor cap from t he dis distributor tributor.. D o

8D - 8


DN

DIAGNOSIS DIAG NOSIS AND T ESTING (C (Con ontinu tinued) ed) n o t r e m o v e c a b l e s f r o m c a p . Remov Removee cable fro from m spark plug. Connect ohmmeter to spark plug termin a l e n d of ca b le le a n d t o cor r e s po pon d in in g e le le ct ct r od od e i n d is is t r ib ib u t or or ca p . R es es is is t a n ce ce s h ou ou l d b e 2 50 50 t o 1 00 00 0 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the term in i n a l e n ds ds of ca b le le . I f r e si sis t a n ce ce is n ot ot w it it h in in specifications as found in the SPARK PLUG CABLE RESISTANCE chart, replace the cable. Test all spark plug cables in this manner. SPARK PLUG CABLE RESISTANCE

MINIMUM

MAXIMUM

250 Ohms Per Inch

1000 Ohms Per Inch

3000 30 00 Oh Ohms ms Pe Perr Fo Foot ot

12,0 12 ,000 00 Oh Ohms ms Pe Perr Fo Foot ot Fig. 13 Normal Operation and Cold (Carbon) Fouling

To t est ignitio ignition n co coil il-to -to--distributor cap cabl cable, e, do n ot remove the cable from the cap. Connect ohmmeter to rotorr button (center conta ct) of distributor roto distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug C a b le le R es es is is t a n ce ce ch a r t , r e m ov ov e t h e ca b le le fr om om t h e distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifica ti t ion s a s fou nd n d in t he h e S p a rk r k P lu lu g C a bl bl e Resistance chart, replace the cable. Inspect the ignition coil coil tower for for cra cks, burn s or corrosio corrosion. n.

SPARK PLUG CONDITIONS NORM AL OPE OPERA RATING TING T h e f e w d e p os os it it s p r e se se n t on t h e s p a r k p lu lu g w il il l probably be light tan or slightly gray in color. This is e vi vi de de n t w it it h m os os t g r a d es es of com m e r ci ci a l g a s ol ol in in e (F i g. g. 1 3) 3). T h e r e w il il l n ot ot b e e vi vi de de n ce ce of e le le ct ct r od od e b u r n i n g. g. O n a l l e n g in in e s e xc xce p t t h e 4 .7 .7 L V-8 , g a p g r ow ow t h w il il l n o t a v er er a g e m or or e t h a n a p p r ox ox im im a t e ly ly 0.025 mm (.001 in) per 3200 km (2000 miles) of operation. On the 4.7L V-8, gap growth will not average more than approximately.0015 in per 3200 km (2000 m i le le s ) of of o p er er a t i on on . S p a r k p lu lu g s t h a t h a v e n or or m a l w ea ea r ca n u s u a l ly ly b e cl ea ea n e d , h a v e t h e e le le ct ct r od od e s filed, have the gap set and then be installed. S om om e fu e l r e fi fi n er er s i n s e ve ve r a l a r e a s of t h e U n i t ed ed States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated w it it h a r u s t col or or e d d e po pos it it . T h is is r u s t col or or ca n b e misdiagnosed as being caused by coolant in the comb u s t io ion ch a m b e r. r. S p a r k p lu lu g p e r fo for m a n c e m a y b e affected by MMT deposits.

COLD FOULING/CARBON FOULING C ol ol d fou l in in g i s s om om e t im im e s r e fe fe r r e d t o a s ca r b on on fouling. The deposits that cause cold fouling are basi-

1 – NO NORM RMAL AL 2 – DRY BLAC BLACK K DEPOSITS DEPOSITS 3 – COLD (CARB (CARBON) ON) FOULING FOULING

cally carbon (Fig. 13). A dry, black deposit on one or two plugs in a set may be caused by sticking valves or def defec ective tive spa rk plug cables. Cold (carbon) (carbon) fouling fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (sho short rt trips) trips)..

WET FOULING OR GAS FOULING A spark plug coated coated wi with th ex exccessi essive ve wet fuel or oil i s w et et fou l ed ed . I n ol de de r e n gi gi n es es , w or or n p is is t on on r i n gs gs , leaking valve gu ide seals or excessive excessive cyli cylinder nder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) control) is achi achieve eved. d. This conditio ndition n can usua l ly ly b e r e so solv ed ed b y cle a n in in g a n d r e in in s t a ll lli ng ng t h e fouled plugs.

OIL OR ASH ENCRUSTED I f on o n e or m or or e s pa pa r k p lu lu gs gs a r e oil or oil a s h encrusted (Fig. 14), evaluate engine condition for the ca u s e of oi l e n t r y i n t o t h a t p a r t i cu cu l a r com b u s t io ion chamber.

ELECTRODE GAP BRIDGING E le l e ct ct r od od e ga p b r id id gi gin g m a y b e t r a ce ce d t o loos e deposits depo sits in the combustio mbustion n cham ber ber.. These deposits deposits a cc ccu m u la la t e on t h e s p a rk r k p lu lu g s d u r in in g con t in in u ou ou s s t op op -a -a n d -g -g o d r i v in in g . W h en en t h e e n gi gi n e i s s u d d en en l y subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes (Fig. 15). This short circ ircuits uits the el elec ectrode trodes. s. Spar k plug plugss wi with th elec el ectrode trode gap bridg bridging ing can be cleaned cleaned using sta ndard procedures.

DN


8D - 9

DIAGNOSIS DIAG NOSIS AND T ESTING (C (Con ontinu tinued) ed)

Fig. 16 Scavenger Deposits 1 – GROUND GROUND ELECTRODE ELECTRODE COVERED COVERED WITH WHITE WHITE OR YELLOW DEPOSITS 2 – CENT CENTER ER ELECTR ELECTRODE ODE

CHIPPED ELECTRODE INSULATOR Fig. 14 Oil or Ash Encrusted

A chipped chipped el elec ectrode trode insulato insulatorr usually results from b en en d in in g t h e ce n t er er e le le ct ct r od od e w h il ile a d ju ju s t in in g t h e spark plug electrode electrode gap. Under certain conditio nditions, ns, s ev ev er er e d et et on on a t io ion ca n a ls l s o s ep ep a r a t e t h e i n su su la l a t or or from the center electrode (Fig. 17). Spark plugs with this condition must be replaced.

Fig. 15 Electrode Gap Bridging 1 – GROUN GROUND D ELECTROD ELECTRODE E 2 – DEPOSI DEPOSITS TS 3 – CENT CENTER ER ELECTRO ELECTRODE DE

SCAVENGE SCA VENGER R DEPOSITS Fuel scavenger deposits may be either white or yell ow ow (F i g. g. 1 6) 6). T h e y m a y a p p ea ea r t o b e h a r m f u l, l, b u t this is a normal conditio ndition n caused by chemic chemical additives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire misfire t endenc endencie ies. s. Notice Notice that acc accumulaumulation on the ground electrode and shell area may be h e a vy vy, b u t t h e d e po pos it it s a r e e a s il il y r e m o ve ve d . S p a r k plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures.

Fig. 17 Chipped Electrode Insulator 1 – GROUN GROUND D ELECTRO ELECTRODE DE 2 – CENTER CENTER ELECTR ELECTRODE ODE 3 – CHIPP CHIPPED ED INSULA INSULATOR TOR

PREIGNITION DAMAGE Preignition Preignitio n damage is usually caused by ex exccessi essive ve com b u s t io ion ch a m b e r t e m p er er a t u r e . T h e ce n t e r e le le cct r o de de d is is s ol ol ve ve s fi r st st a n d t h e g r ou ou n d e le le ct ct r od od e d is is solv so lves es so somewhat mewhat latter (Fig. 18). 18). Insulators appear relativel relativ ely y deposit deposit free. Determine if th e spark plug h a s t h e cor r e ct ct h e a t r a n ge g e r a t in i n g for t h e e n gi gi n e. e. Determine if ignitio ignition n timing is ove verr advance advanced d or if

8D - 10


DN

DIAGNOSIS DIAG NOSIS AND T ESTING (C (Con ontinu tinued) ed) other operating conditio nditions ns are causing engi engine ne overh e a t i n g. g. ( Th Th e h e a t r a n g e r a t i n g r e fe fe r s t o t h e op e r a t in g t e m pe pe r a t u re r e of a p a r t ic icu la l a r t yp y p e s pa p a r k p lu lu g. g. Spark plug plugss are desi designed gned to operate wi within thin spec specif ific ic t e m pe pe r a t u r e r a n ge ge s. s. T h is is d ep ep en en d s u p on on t h e t h ic i ck n e s s a n d l en en g t h of t h e ce n t e r e le le ct ct r od od es es p or or ce ce la la i n insulator.)

Fig. 18 Preignition Damage 1 – GROUND ELECTRODE ELECTRODE STARTING STARTING TO DISSOLVE DISSOLVE 2 – CENTER CENTER ELECTRODE ELECTRODE DISSOL DISSOLVED VED

SPARK PLUG OVERHEATING Overheating is indicated by a white or gray center elec el ectrode trode insulator tha t also appears bli blistered stered (Fig. 19).. The inc 19) increase rease in el elec ectrode trode gap wil willl be conside nsiderrably in excess of 0.001 inch per 2000 miles of operat i on on . T h is is s u g ge ge s t s t h a t a p lu lu g w it it h a cool er er h e a t range rating should be used. Over advanced ignition timing,, deto timing detonat nat io ion n and cooli ling ng sys system tem malf malfunctio unctions ns can also cause spark plug overheating.

Fig. 19 Spark Plug Overheating 1 – BLISTERED WHITE OR GRAY GRAY COLORED INSULAT INSULATOR OR

IGNITION SWITCH AND KEY LOCK CYLINDER ELECTRICAL DIAGNOSIS For ig ignitio nition n swi switch tch el elec ectric trical al sc schematic hematics, s, ref refer er to Ignition Switch in Group 8W, Wiring Diagrams.

MECHANICAL DIAGNOSIS (KEY DIFFICULT TO ROTATE) Ve h i c le l e s e q u i pp p p e d w i t h a n a u t o m at at i c t r a n s le i s m i s s i o n a n d a f l o o r m o u n t e d s h i f t e r : a ca b le used to connect connect t he interlo interlocck dev devic icee in the steeri steering ng col u m n a s s em em b ly ly, t o t h e t r a n s m i s si si on on fl oo oor s h i ft ft lever. This interlock device is used to lock the transmissio missi on shif shifter ter in the PA PARK RK positio position n when the key locck cyl lo ylinder inder is r otated to t he LOC LOCKED KED or ACCESSORY position. The interlock device within the steering column column is n ot servic serviceable. eable. If repair is n ec ecessary essary,, t h e s t ee ee r in in g colu m n a s se s e m bl bly m u s t b e r e pl pla ce ce d. d. Refer to Group 19, Steering for procedures. If the ig ignitio nition n key is dif difffic icult ult to r otate to or from t h e L OC OC K or AC CE CE S S O RY RY p o si si t io ion , i t m a y n ot ot b e the fault of the key cylinder or the steering column compo mponents. nents. The brake tran smissi smissio on shif shiftt interlo interlocck ca bl b le m a y b e ou t of a d ju ju s tm t m en e n t . R ef efe r t o B ra ra k e Tr a n s m i ss ss io ion S h if ift I n t e r lo lock C a b le le Ad ju ju s t m e n t i n Group 21, Transmissions for adjustment procedures. Ve h i c le l e s e q u i pp p p e d w i t h a n a u t o m at at i c t r a n s mission and a steering column mounted shifter: an interlock device is located within the steering column. This interlock device is used to lock the transmissio missi on shif shifter ter in the PA PARK RK positio position n when the key l oc ock cy li li n de de r i s i n t h e L O CK CK E D or AC CE CE S S O RY RY position. If it is difficult to rotate the key to or from t h e L OC OC K or AC CE CE S S O RY RY p os os it it i on on , t h e i n t er er l oc ock device within the steering column may be defective. This d evi evice ce is not servic serviceable. eable. If repair is necessary, necessary, t h e s t ee ee r in in g colu m n a s se s e m bl bly m u s t b e r e pl pla ce ce d. d. Refer to Group 19, Steering for procedures. Ve h i c le l e s e q u i pp p p e d w i t h a m a n u a l t r a n s m is is s i o n a n d a f l o o r m o u n t e d s h i f t e r : on certain models, a lever is located on the steering column behind t h e i gn gn i t io ion k e y l oc ock cy li li n de de r. r. T h e l ev ev er er m u s t b e man ually operated operated to a ll llo ow rotatio rotation n of th e ig ignitio nition n key lock cylinder to the LOCK or ACCESSORY position. If it is difficult to rotate the key to the LOCK or ACCESSOR AC CESSORY Y positio position, n, the le lever ver mec mechanism hanism may be d e fe fe ct ct i ve ve . T h is is m e ch ch a n i s m i s n ot ot s er er v ic ice a b le le . I f r e p a ir ir i s n e ce ce s sa sa r y, y, t h e s t e er er i n g col u m n a s s em em b ly ly m u s t b e r e p la la ce ce d . R e fe fe r t o G r ou ou p 1 9, 9, S t e er er i n g for procedures. On other models, the ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSOR AC CESSORY Y positio position. n. If it is dif difffic icult ult to rotate the key to the LOCK or ACCESSORY position, the lock mechan mec han ism within the steeri steering ng column may be defec defec-tive.. This mec tive mechan han ism is not servi servicceabl eable. e. If r epair is

DN


8D - 11

DIAGNOSIS DIAG NOSIS AND T ESTING (C (Con ontinu tinued) ed) n e ce ce ss ss a r y, y, t h e s t e er er i n g col u m n a s s em em b ly ly m u s t b e replaced. Refer to Group 19, Steering for procedures.

REMOVAL AND INSTALLATION SPARK PLUG CABLES CAUTIO CAUT ION: N: Wh When en di disc scon onne nect ctin ing g a hi high gh vo volt ltag age e cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose (Fig. 20). Grasp the boot (not the cable) and pull it off with a steady, even force.

W h en en r e p la la ci ci n g t h e s p a r k p lu lu g a n d coi l c a bl bl es es , r ou ou t e t h e ca b le le s cor r e ct ct l y a n d s e cu cu r e i n t h e p r op op e r r e t a in in e r s . F a i lu lu r e t o r ou ou t e t h e ca b le le s p r op op e r ly ly ca n cause the radio to repro reproduce duce ignitio ignition n noi noise. se. It could also cause cross ignition of the plugs or short circuit the cables to ground. When insta ll lling ing new cable ables, s, ma ke sure a po positi sitive ve con n e ct ct i on on i s m a d e . A s n a p s h ou ou l d b e fe lt lt w h e n a good connection is made between the plug cable and the distributor cap tower.

SPARK SPA RK PLUGS REMOVAL On 3.9L V-6 V-6 an d 5.2/ 5.2/5.9L 5.9L VV-8 engines, spa rk plug cable heat shields are pressed into the cylinder head to sur round eac each h cable boo boot and spark plug (Fig. (Fig. 22). 22).

Fig. 20 Cable Removal 1 2 3 4

– – – –

SPARK PLUG SPARK PLUG CABLE AND BOOT BOOT SPARK SP ARK PLUG PLUG BOOT PULLER PULLER TWIST TWI ST AND PULL PULL SPARK SP ARK PLU PLUG G

Install cables into the proper engine cylinder firing order (Fig. 21).

Fig. 21 Engine Firing Order—5.2/5.9L V-8 Engine

Fig. 22 Heat Shields—3.9/5.2/5. Shields—3.9/5.2/5.9L 9L Engine Engines s 1 – AIR GAP 2 – SPARK SPARK PLUG PLUG BOOT HEAT HEAT SHIELD SHIELD

I f r e m ov ova l of t h e h e a t s h ie ie ld ld (s (s ) i s n e ce ce ss ss a r y, y, remove the spark plug cable and compress the sides of shield shield fo forr removal. Ea ch shield is slo slotted tted to a llo llow w for compressi mpressio on and remov removal. al. To install the shiel shields, ds, a l ig ig n s h ie ie ld ld t o m a ch ch i n ed ed op e n in in g i n cy li li n d er er h e a d and tap into place with a block of wood. 4 .7 .7 L V– 8 E n g in in e : E a ch i n di di vi vi du du a l s p a r k p lu lu g i s located under each ignition coil. Each individual ignit i on on coi l m u s t b e r e m ov ov ed ed t o g a i n a cc cce ss ss t o e a ch ch spark plug plug.. Ref Refer er to Igni Ignitio tion n Co Coil il Removal/ Removal/InstallaInstallation. (1 ) E x ce ce p t 4 .7 .7 L E n g in in e : P r i or or t o r e m ov ov in in g s p a r k p lu lu g , s p r a y com p r e ss ss e d a i r a r ou ou n d s p a r k p lu lu g h ol ol e and area around spark plug. This will help prevent foreign material from entering combustion chamber. (2)) 4.7L V–8 (2 V–8 En gine: Pr io iorr t o removing removing spar k plug, spray compressed a ir around base of ignitio ignition n coil at cylinder head. This will help prevent foreign material from entering combustion chamber.

8D - 12


DN

REMOVAL REMOV AL AND INSTALL INSTALLA ATION (Co (Continued) ntinued) (3) Remove spark plug from cylinder head using a q ua u a li lit y s oc ock et et w it it h a r u bb bb er er or foa m in s er er t . I f equipped with a 4.7L V-8 engine, also check condition of coil o-ring and replace as necessary. (4) Exce Except pt 4.7L 4.7L:: Always Always remove spar k plug or ignition tio n coil cables cables by grasping at the cable boot boot (Fig. 2 0) 0). Tu r n t h e ca b le le b oo oot 1 /2 /2 t u r n a n d p u l l s t r a i gh gh t back bac k in a steady motion. motion. N ev ever er pull directly directly on th e cable. Internal damage to cable will result. (5 ) I n s p ec ect s p a r k p lu lu g con d i t io ion . R ef e fe r t o S p a r k Plug Conditions.

CLEANING T h e p lu lu g s m a y b e cle a n ed ed u s in in g com m er e r ci cia ll lly available spark plug cleaning equipment. After cleaning, fil filee the center el elec ectrode trode flat flat with a small point point file or jewelers file before adjusting gap.

CAUTION: Never use a moto CAUTION: motorized rized wire wheel brush to cl clea ean n th the e sp spar ark k pl plug ugs. s. Me Meta tall llic ic de depo posi sits ts wi will ll remain rem ain on the spark plug ins insula ulator tor and will cause plug misfire.

GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If t h e ga p is n ot ot cor r ec ect , a d ju ju s t it b y b en en d in in g t h e ju s t ground electrode (Fig. 23). N e v e r a t t e m p t t o a d ju t h e g a p b y b e n d i n g t h e c e n t e r e l e c tr tr o d e .

INSTALLATION CAUTIO CAUT ION: N: Th The e 4. 4.7L 7L V– V–8 8 en engi gine ne is eq equip uippe ped d wit with h copp co pper er co core re gr grou ound nd ele elect ctro rode de sp spar ark k pl plug ugs. s. Th They ey must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. Special care should be taken when installing spark p lu lu g s i n t o t h e cy li li n de de r h e a d s p a r k p lu lu g w el el ls ls . B e sure the plug plugss do not drop into the plug wells wells as el elec ec-trodes can be damaged. Always tighten spark plugs to the specified torque. O ve ve r t i gh gh t e n in in g ca n ca u s e d is is t or or t i on on r e s u lt lt i n g i n a change in the spark plug gap or a cracked porcelain insulator. E x ce ce pt pt 4 .7 .7 L E n g in in e : Wh e n r e pl pla ci cin g t h e s p a rk rk plug a nd ig ignitio nition n coil cables, cables, r oute the cable abless correctly and secure them in the appropriate retainers. F a i lu lu r e t o r o u t e t h e ca b le le s p r op op e r ly ly ca n ca u s e t h e radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. (1) Start the spark plug into the cylinder head by hand to avoid cross threading. (2 ) E xc xce p t 4 .7 .7 L E n g in in e : T i gh gh t e n s p a r k p lu lu g s t o 35-41 N·m (26-30 ft. lbs.) torque. (3) E xc xcept ept 4.7 4.7L L Engine: Install spa rk plug cables cables over spark plugs. (4 ) 4 .7 .7 L V– 8 E n g in in e : T ig ig h t en en s p a r k p lu lu g s t o 2 7 N·m (20 ft. lbs.) torque. (5 ) 4 .7 .7 L V– 8 E n g in in e : B ef efor e i n st st a l li li n g coi l( l(s ), ), chec heck k conditio ndition n of coil o-ring and replac replacee as nec necesessary.. To a id in co sary coil il inst allation, a pply silicone silicone to co coil il o-ring. (6)) 4.7L V–8 E ngine: In sta ll ignition (6 ignition co coil( il(s). s). Refer Refer to Ignitio Ignition n Co Coil il Removal/Insta Removal/Insta ll llat at io ion. n.

IGNITIO IG NITION N COIL— 3. 9/5. 2/5. 9L ENG NGINE INES S The ignition coil is an epoxy filled type. If the coil is replaced, it must be replaced with the same type.

REMOVAL The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head (Fig. 24). This bracket is mounted on top of the automatic belt tensioner bracket using common bolts. (1) Disc Disconnect the primary wi wiring ring from the ig igninition co coil. il. (2)) Disc (2 Disconnec onnectt t he seconda seconda ry spa rk plug cable cable from from the ignition coil.

Fig. 23 Setting Spark Plug Gap—Typical 1 – GA GAUG UGE E 2 – SPARK SPARK PLU PLUG G

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8D - 13

REMOVAL REMOV AL AND INSTALL INSTALLA ATION (Co (Continued) ntinued) 25) is used to seal the coil at the opening into the cylinder head. (1)) Depending on wh ic (1 ich h co coil il is being rem oved, the throttle body air intake tube or intake box may need to be removed to gain access to coil. (2)) Disc (2 Disconnec onnectt elec electr tr ic ical al co connector nnector (Fig (Fig.. 26) from coil by pushing do downward wnward on rele release ase lo locck on top of connec onnector tor an d pull co conn nn ec ector tor from coi oil. l. (3) Cl Clean ean area at base of co coil with with compressed air before removal. (4) Remo Remove ve coil coil mounting nu t from m ounting stud (Fig. 26). (5)) Carefully pull up co (5 coil il from from cylinder cylinder head ope openning with a slight twisting action. (6) Remove coil coil from vehicl vehicle. e.

Fig. 24 Ignition Coil—3.9L V-6 or 5.2/5.9L V-8 Engines 1 2 3 4

– – – –

ACCESSORY ACCESSOR Y DRIVE BELT BELT TENSIONER TENSIONER COIL CONN CONNECTO ECTOR R IGNITI IGN ITION ON COIL COIL COIL MOUN MOUNTING TING BOL BOLTS

WARNING: DO NOT REMOVE THE COIL MOUNTING WARNING: MOUNTING BRACKET-TOBRACKET -TO-CYLINDE CYLINDER R HEAD MOUNTIN MOUNTING G BOL BOLTS. TS. THE COIL MOUNTING BRACKET IS UNDER ACCESSORY DRIVE BELT TENSION. IF THIS BRACKET IS TO BE RE REMOV MOVED ED FO FOR R ANY RE REAS ASON ON,, ALL BE BEL LT TENS TE NSION ION MUS MUST T FI FIRS RST T BE RE RELI LIEV EVED ED.. RE REFE FER R TO THE BELT SECTION OF GROUP 7, COOLING SYSTEM. (3 ) R em em ov ov e ig n it it io i on bracket (two bolts).

coi l

fr om om

coi l

m ou ou n t in in g

INSTALLATION (1) Install the ignition coil to coil bracket. If nuts a n d b ol ol ts t s a r e u s ed ed t o s ec ecu r e coil t o coil b r a ck ck et et , t i gh gh t e n t o 11 N · m (1 00 00 i n . l b s .) .) t or or q u e . I f t h e coi l mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 N·m (50 in. lbs.) torque. (2) Co Conn nn ec ectt all wiring to ignition ignition co coil il..

IGNITION IGNITIO N COIL— COIL— 4. 7L ENGINE ENGINE REMOVAL An indi indivi vidual dual ig ignitio nition n coil is used for eac each h spark plug (Fig. 25). The coil fits into machined holes in the cylinder head. A mounting stud/nut secures each coil to the top of the intake manifold (Fig. 26). The bottom of the coil is equipped with a rubber boot to seal the spark plug to the coil. Inside each rubber boot is a spring. The spring is used for a mechanical contact between the coil and the top of the spark plug. These rubber boots and springs are a permanent part of the coil an d are not servi servicced separately separately.. An o-ring (Fig.

Fig. 25 Ignition Coil—4.7L V–8 Engine 1 – OO-RI RING NG 2 – IGNITIO IGNITION N COIL COIL 3 – ELEC ELECTRICA TRICAL L CONNECT CONNECTOR OR

INSTALLATION (1) Using compr (1) compr essed air, blow blow out an y dirt or contaminants from around top of spark plug. (2) Check Check conditio ndition n of coil o-ring and replac replacee as necessary.. To aid in coi necessary oill insta ll llation, ation, apply sili siliccone t o coil o-ring. (3)) Positio (3 Position n ignitio ignition n co coil il into cylinder cylinder head ope opening ning and push onto spark plug. Do this while guiding coil base over mounting stud. (4) Install mounting stud nut and tighten to 8 N·m (70 in. lbs.) torque. (5)) Co (5 Connect nnect elec electrical trical conn conn ec ector tor to coil coil by sn apping into posi positio tion. n. (6 ) I f n e ce ce s sa sa r y, y, i n st st a l l t h r o t t le le b od od y a i r t u b e or box.

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REMOVAL REMOV AL AND INSTALL INSTALLA ATION (Co (Continued) ntinued)

Fig. 27 Crankshaft Position Sensor—3.9/5.2/5.9L Engines Fig. 26 Ignition Coil Location—4.7L V–8 Engine 1 – IGN IGNITI ITION ON COIL COIL 2 – COIL ELECTR ELECTRICAL ICAL CONNE CONNECTOR CTOR 3 – COIL MOUNTING MOUNTING STUD/NU STUD/NUT T

1 2 3 4 5

– – – – –

GROMMET GROMME T MOUNTING MOUNT ING BOLT BOLTS S (2) CRANKSHA CRAN KSHAFT FT POSITION POSITION SENSOR SENSOR RIGHT EXHAU EXHAUST ST MANIFOLD MANIFOLD TRANSMISS TRAN SMISSION ION BELL BELL HOUSING HOUSING

CRA RANK NKSHA SHAFT FT PO POSITIO SITION N SE SENSO NSOR— R— 3. 9/5. 2/ 5. 9L ENGINE NGINES S

CRANKSHAFT CRANKSHA FT POSITION POSITION SENSOR— SENSOR— 4. 7L V-8 ENGINE

REMOVAL

REMOVAL

The sensor is bolted to the top of the cylinder block n e a r t h e r e a r of r i gh gh t cy li li n d er er h e a d (F i g. g. 2 7) 7 ). T h e sensor is accessed by removing the right front fender liner. (1) Remove right front tire and right front wheelh ou ou s e lin e r. r. R ef efe r t o F r on on t Wh e el elh ou ou s e L in in e r in Group 23, Body. (2) Disc Disco onnect crank shaft po positi sitio on senso sensorr pig pigtail tail harness from main wiring harness. (3) Remove two sensor (recessed hex head) mounting bolts (Fig. 27). (4) Remove sensor from engine.

The Crankshaft Position (CKP) sensor is located at the rig right-rear ht-rear sid sidee of th e engi engine ne cyl ylinder inder bl blo ock (Fig. 28). It is positioned and bolted into a machined hole in the engine block. (1)) Disc (1 Disconnec onnectt CKP ele electric ctrical al connec onnector tor at sensor sensor.. (2)) Remov (2 Removee CKP mount ing bolt bolt (Fig. 28). 28). (3) Carefully Carefully pry senso sensorr from cyl ylinder inder bl blo ock in a rocking action with two small screwdrivers. (4)) Remov (4 Removee sensor fro from m vehic vehicle. le. (5)) Check condition (5 condition of sensor oo-ring. ring.

INSTALLATION (1) Position crankshaft position sensor to engine. (2) Install mounting bolts bolts and tig tighten hten to 8 N·m (70 in. lbs.) torque. (3) Connect Connect main harn ess el elec ectric trical al connecto nnectorr to sensor. (4 ) I n s t a l l r i gh gh t fr on on t t i r e a n d r i gh gh t fr on on t w h e el el h ou ou s e lin e r. r. R ef efe r t o F r on on t Wh e el elh ou ou s e L in in e r in Group 23, Body.

INSTALLATION (1) Clean out machined hol (1) holee in engine block. block. (2 ) A p pl pl y a s m a ll ll a m ou ou n t of e n gi gi n e oi l t o s e n so sor o-ring. (3) Install senso sensorr into engine bloc block wi with th a sli slight ght rocking roc king a ctio tion. n. Do not twist senso sensorr into positio position n as damage to o-ring may result.

CAUTION: Befor CAUTION: Before e tight tightening ening sensor mounting bolt, be su sure re se sens nsor or is co comp mple lete tely ly fl flus ush h to cy cyli lind nder er bloc bl ock. k. If se sens nsor or is no nott fl flus ush, h, da dama mage ge to se sens nsor or mounting tang may result.

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Fig. 29 Camshaft Position Sensor 1 2 3 4

Fig. 28 CKP Sensor Location/Removal/Installation— 4.7L V–8 Engine 1 – CRAN CRANKSHA KSHAFT FT POSITION POSITION SENSOR SENSOR 2 – MOUNTING MOUNTING BOL BOLT T

– – – –

SYNC SIGNAL SIGNAL GENERA GENERATOR TOR CAMSHAFT CAMS HAFT POSITION POSITION SENSO SENSOR R PULSE PUL SE RIN RING G DISTRIBUT DISTR IBUTOR OR ASSEMB ASSEMBL LY

(5)) Insta ll air cleaner (5 cleaner assembly assembly..

CAM CA M SHAF SHAFT T POSITION POSITION SENSOR— SENSOR— 4. 7L ENGINE ENGINE The Camshaft Posi Positio tion n Senso Sensorr (CMP) on on the 4. 4.7L 7L V–8 engine is bolted to the front/top of the right cylinder head (Fig. 30).

(4 ) I n s t a ll ll m ou ou n t i n g b o lt lt a n d t i gh gh t e n t o 2 8 N · m (21 ft. lbs.) torque. (5) Co Conn nn ec ectt ele electric ctrical al connector onnector to sensor sensor..

CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the distributor on all 3.9L V-6 and 5.2/5.9L V-8 engines (Fig. 29).

REMOVAL D is is t r i bu bu t o r r e m ov ov a l i s n ot ot n e ce ce s sa sa r y t o r e m ov ov e camsha ft posi positio tion n sensor sensor.. (1) Remov Removee a ir cleaner assembly assembly.. (2) Disc Disco onn ec ectt negative cable from ba tter y. (3) Remove Remove distri distributor butor cap from distri distributor butor (two screws). (4 ) D is is co con n e ct ct ca m s h a ft ft p os os it it i on on s e n so sor w ir ir i n g harness from main engine wiring harness. (5) Remove distributor rotor from distributor shaft. (6 ) L if ift t h e ca m s h a ft ft p os os it it i on on s e n so sor a s s em em b ly ly from the distributor housing (Fig. 29).

INSTALLATION (1) Install camsha ft po positi sitio on senso sensorr to dis distributor tributor.. Align sensor into notch on distributor housing. (2) Connect wiring harness. (3) Install rotor. (4 ) I n st s t a ll l l d is is t r ib ib u t or or ca p . Tigh t e n m ou ou n t in in g screws.

Fig. 30 CMP Location—4.7L Engine 1 2 3 4

– – – –

RIGHT CYLIN CYLINDER DER HEAD HEAD CAMSHAFT CAMS HAFT POSITION POSITION SENSO SENSOR R MOUNTING MOUNT ING BOL BOLT T ELEC.. CONNECTO ELEC CONNECTOR R

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REMOVAL I t i s e a s ie ie r t o r e m ov ov e/ e/i n st st a l l s e n so sor fr om om u n d e r vehicle. (1) Raise and support vehicle. (2) Disconn Disconn ec ectt elec electrical trical connector connector at CMP sensor (Fig. 30). (3) Remove sensor mounting bolt (Fig. 30). (4 ) C a r e fu fu l ly ly p r y s e n so sor fr om om cy li li n de de r h e a d i n a rocking action with two small screwdrivers. (5) Check co condition ndition of sensor sensor oo-ring. ring.

damper is aligned to 0 degree (TDC) mark on timing chain co cover ver (Fig. 31). 31).

INSTALLATION (1) Clean out machined hole in cylinder head. (2 ) A p p ly ly a s m a ll ll a m ou ou n t of e n g in in e oi l t o s e n so sor o-ring. (3) Install sensor into cylinder head with a slight rocking roc king a ctio tion. n. Do not twist senso sensorr into positio position n as damage to o-ring may result.

CAUTION: Befor CAUTION: Before e tight tightening ening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result. (4 ) I n s t a ll ll m ou ou n t i n g b o lt lt a n d t i gh gh t e n t o 1 2 N · m (106 in. lbs.) torque. (5) Co Conn nn ec ectt ele electric ctrical al connector onnector to sensor sensor.. (6) Lower vehicle vehicle..

DISTRIBUTO DISTRIB UTORS— RS— 3. 9/5. 2/5. 9L ENGINE NGINES S

Fig. 31 Damper-To-Cover Alignment Marks—Typical 1 – ALIGN ALIGNMENT MENT MARK 2 – TIMING CHAIN CHAIN COVER COVER MARKS MARKS 3 – CRANKSHAFT VIBRA VIBRATION TION DAMPER

(8) The distributor distributor roto rotorr shoul should d now be aligned aligned to the CYL. NO. 1 alignment mark (stamped) into the camsha ft po positi sitio on senso sensorr (Fig Fig.. 32) 32).. If not, rotate the cr a n k s h a ft ft t h r ou ou gh g h a n ot ot h e r com p le le t e 3 60 60 d eg eg re re e t u r n . N ot ot e t h e p os os it it i on on of t h e n u m b e r on e cy li li n d er er s p a r k p lu lu g ca b le le (on t h e ca p ) i n r e la la t i on on t o r ot or or . Rotor should now be aligned to this position.

REMOVAL CAUTION: Base ignition CAUTION: ignition timing is not adjustable adjustable on any engine. Distributors do not have built in centrifugal ug al or va vacu cuum um as assi sist sted ed ad adva vanc nce. e. Ba Base se ig ignit nition ion timi ti ming ng an and d ti timi ming ng ad adva vanc nce e ar are e co cont ntro rolle lled d by th the e Powert Pow ertrai rain n Con Contro troll Mod Module ule (PC (PCM). M). Bec Becaus ause e a con con-ventional timing light can not be used to adjust distributor tribut or positio position n after installation, installation, note position of distributor before removal. (1) Remov Removee a ir cleaner assembly assembly.. (2) Disc Disco onn ec ectt negative cable from ba tter y. (3) Remove Remove distri distributor butor cap from distri distributor butor (two screws). (4 ) M a r k t h e p os os it it i on on of d is is t r ib ib u t or or h ou ou s in in g i n relationship to engine or dash panel. This is done to aid in installation. (5) Bef Befo ore distri distributor butor is remov removed, ed, the num ber one cy li li n d er er m u s t b e b r o u gh gh t t o t h e Top D ea ea d C en en t e r (TDC) firing position. (6 ) At At t a ch ch a s oc ock e t t o t h e C r a n k s h a ft ft Vi br br a t i on on Damper mounting bolt. (7) Slo Slowly wly rotat e engine cloc clockwise, as vie viewed wed fro from m front, un til indicating indicating mark on cran kshaft vi vibratio bration n

Fig. 32 Rotor Alignment Alignment Mark—3 Mark—3.9/5.2/5 .9/5.2/5.9L .9L Engines 1 – CAMS CAMSHAFT HAFT POSITION POSITION SENSOR SENSOR ALIGNMENT ALIGNMENT MARK 2 – ROTOR 3 – DISTR DISTRIBUT IBUTOR OR

(9 ) D is is co con n e ct ct ca m s h a ft ft p os os it it i on on s e n so sor w ir ir i n g harness from main engine wiring harness. (1 0) 0) R em em ov ov e d is is t r ib ib u t or or r ot ot or or fr om om d is is t r ib ib u t or or shaft.

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8D - 17

REMOVAL REMOV AL AND INSTALL INSTALLA ATION (Co (Continued) ntinued) (11) Remo Remove ve dis distributor tributor hol holddo ddown wn clamp bo bolt lt and clamp cl amp (Fig (Fig.. 33) 33).. Remov Removee distributor from vehic vehicle. le.

(8) Connect Connect camsha ft po positi sitio on senso sensorr wi wiring ring harn e s s t o m a i n e n gi gi n e h a r n e s s . (9 ) I n st s t a ll ll d is is t r ib ib u t or or ca p . Tig h te t e n m ou ou n t in in g screws. (10) Refer Refer to the foll llo owing wing,, Chec Checking king Dis Distributo tributorr Position.

CHECKING DISTRIBUTOR POSITION To verify correct distributor rotational position, the DRB scan tool must be used.

WARNING: WHEN PERFORMING THE FOLLOW WARNING: FOLLOWING ING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAN AND D IN LIN INE E WITH THE FAN BLAD BL ADES ES OR FAN BE BEL LT. DO NO NOT T WE WEAR AR LO LOOS OSE E CLOTHING.

Fig. 33 Distr Distributor ibutor Holddown Clamp— Clamp—3.9/5.2 3.9/5.2/5.9L /5.9L Engines 1 – CLA CLAMP MP BOL BOLT T 2 – HOLDDO HOLDDOWN WN CLAMP CLAMP 3 – DISTR DISTRIBUT IBUTOR OR HOUSING HOUSING

CAUTION CAUT ION:: Do no nott cr cran ank k en engi gine ne wi with th di dist stri ribu buto torr removed. remov ed. Distri Distributor butor/crank /crankshaft shaft relat relationship ionship will be lost.

INSTALLATION I f e n gi gin e h a s b ee ee n cr a n k ed e d w h il il e d is is t r ib ib u t or or is removed, establish the relationship between distributor shaft and number one piston position as follows: R ot ot a t e cr a n k s h a ft ft in a clock w is is e d ir ir e ct ct io i on , a s viewe vi ewed d from front, u ntil number one cyl ylinder inder pisto piston n is a t top of compr compr essio ession n stroke (co compression mpression sh ould b e fe l t on fin ge ge r w i t h n u mb m b e r on e s pa pa r k p lu lu g r e m ov ov ed ed ). ). T h e n con t i n u e t o s lo low ly ly r ot ot a t e e n gi gi n e clockwise until indicating mark (Fig. 31) is aligned to 0 degree (TDC) mark on timing chain cover. (1 ) Cl Cl ea ea n t op op of cy li li n de de r b lo lock for a g oo ood s e a l between distributor base and block. (2) Lightly oil the rubber o-ring seal on the distributor housi housing. ng. (3) Install rotor to distributor shaft. (4) P ositi sitio on distri distributor butor into engine to its origi riginal nal position. Engage tongue of distributor shaft with slot in dis distributor tributor oil pump driv drivee ge gear. ar. Positio Position n roto rotorr to the number one spark plug cable position. (5) Insta ll distributor distributor hol holddo ddown wn clamp and clamp bolt. Do not tighten bolt at this time. (6 ) Ro Rot a t e t h e d is is t r i bu bu t o r h ou ou s in in g u n t i l r ot ot or or i s aligned to CYL. NO. 1 alignment mark on the camsha ft position position sensor (Fig. 32). 32). (7) Ti Tighten ghten clamp hol holddo ddown wn bo bolt lt (Fig. 33) t o 22.5 N·m (200 in. lbs.) torque.

(1) Co Connect nnect DRB scan too tooll t o dat a li link nk connecto nnector. r. The data link connector is located in passenger compartment, below and to left of steering column. (2) Gain acc access ess to SET SY SYNC NC sc screen reen on DRB DRB.. (3 ) F ol ollow d ir ir e ct ct io ion s on D RB RB s cr cr e en en a n d s t a r t engine. Bring to operating temperature (engine must be in “closed loop” mode). (4) With engine running at i d le le s p e e d, d, the words I N R AN AN G E s h ou ou l d a p p ea ea r on s cr cr e en en a l on on g w it it h 0 °. °. This ind ic icat at es correct correct distributor posi position. tion. (5) If a plus (+) (+) or or a minus (-) is displayed displayed next to d e gr gr e e n u m b e r, r, a n d /o /or t h e d e gr gr e e d is is p la la y ed ed i s n ot ot zero,, loose zero loosen n but do not r emov emovee distr ibutor h olddo lddown wn cla m p b ol olt . R ot ot a t e d is is t r ib ib u t or or u n t il il I N R AN AN G E a p p ea ea r s on s cr cr e en en . C on on t in in u e t o r ot ot a t e d is is t r ib ib u t or or u n t il i l a ch ch ie i e vi vin g a s cl os os e t o 0 ° a s p os os si s i bl ble . Aft e r adjustment, tighten clamp bolt to 22.5 N·m (200 in. lbs.) torque. The deg degree ree sc scale ale on SET SY SYNC NC sc screen reen of DRB is ot referring ref erring to fuel sync synchroniz hronizatio ation n only nly.. I t i s n ot eca u s e of t h i s , d o r e fe f e r r in i n g t o i g n i t i o n t i m i n g . B ec n ot ot a t t e mp m p t t o a d ju ju s t i gn gn it i t io i on t im i m in in g u s in in g t h is is method. Rotating dis distributor tributor wil willl have no ef efffec ectt on ignitio ig nition n timing timing.. All All ig ignitio nition n timing values are controlled by powertrain control module (PCM). After testing, install air cleaner assembly.

IGNITION SWITCH AND KEY CYLINDER T h e i gn gn i t io ion k e y m u s t b e i n t h e k e y c yl yl in in d e r for cylinder removal.

KEY CYLINDER REMOVAL (1) Disc (1) Disconnec onnectt negative cable from ba tter y. (2) If equipped equipped wi with th til tiltt column, remov removee til tiltt le leve verr by turning it counterclockwise. (3)) Remov (3 Removee u pper an d lower covers covers (shrouds) from from steering column (Fig. 34). (4) If equipped equipped wi with th automatic tr ansmissio ansmission, n, plac placee shifter in PA PARK RK position. position.

8D - 18


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Fig. 35 Retaining Pin 1 – IGN IGNITIO ITION N SWITCH SWITCH 2 – KEY/KEY KEY/KEY CYLINDE CYLINDER R (RUN POSITION) POSITION) 3 – RET RETAININ AINING G PIN PIN

Fig. 34 Shroud Removal/Installation—Typical 1 2 3 4 5 6 7 8 9

– – – – – – – – –

NUT STEERING STEE RING WHEE WHEEL L TILT TIL T LEVER LEVER UPPER UPP ER SHR SHROUD OUD PANEL BRAC BRACKET KET SPACE SP ACER R NUT LOWER LOW ER SHRO SHROUD UD CLOCK CLO CK SPR SPRING ING

(5 ) A r e t a in in i n g p in in (F i g. g. 3 5) 5) i s l oc oca t e d a t s id id e of key cylinder assembly. (a) Rotate key to RUN position. (b ) P r e s s i n on r e t a in in i n g p i n w h il il e p u l li li n g k e y cyli ylinder nder fro from m ignitio ignition n switc switch. h.

IGNITION SWITCH REMOVAL (1) Remove Remove key lo locck cyl ylinder inder.. Ref Refer er to previ previo ous steps. (2 ) R em em ov ov e 3 i gn gn i t io ion s w it it ch ch m ou ou n t i n g s cr cr e ws ws (F ig i g. 3 6) 6). U s e t a m p er er p r oo oof t or or x b it it (S n a pp -O n ௡ SDMTR10 or equivalent) to remove screws. (3) Gently pull swi switch tch away from column. Rel Release ease connecto nnectorr lo loccks on 77-terminal terminal wi wiring ring connecto nnectorr at ignition switch and remove connector (Fig. 37). (4) Release connector lock on 4-terminal halo lamp wiring conn conn ec ector tor and remove conn conn ec ector tor (Fig. 37). (5) Disc Disco onn ec ectt elec electronic tronic “PRNDL” from switc switch h (i (if f equipped).

IGNITION SWITCH AND KEY CYLINDER INSTALLATION If install installing ing i g n it i t i on o n k e y l o ck c k c y li l i n d e r o n l y, y, proceed to following steps 2, 3 and 4. Also refer to fol-

Fig. 36 Switch Mounting Screws 1 2 3 4

– – – –

IGNITION IGNITIO N SWITCH SWITCH SLOTS NOT ALIGN ALIGNED ED SLOTS ALIGN ALIGNED ED IGNITION IGNITIO N SWITCH MOUNTIN MOUNTING G SCREWS SCREWS (3)

lowing steps 12 t hrough 18. If installing lowing installing bo both th swi switch tch and key cylinder, refer to steps 1 through 18. (1)) Ro (1 Rotat tat e flag (Fig. (Fig. 38) on r ear of ignitio ignition n switc switch h u n t il il i n R U N p os os it it io i on . T h is is s t ep ep m u s t b e d on on e t o allo all ow tan g (Fig. 39) on on key cyli cylinder nder to fit into slots slots (Fig. 36) within ignition switch.

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Fig. 37 Ignition Switch and Halo Lamp Connectors 1 2 3 4 5

– – – – –

KEY-IN SWITCH KEY-IN SWITCH & HALO LIGHT LIGHT MULTI-FU MUL TI-FUNCTIO NCTION N SWITCH SWITCH TURN SIGNAL SIGNAL SWITC SWITCH H & LEVER LEVER IGNITI IGN ITION ON SWITC SWITCH H SPEED SPE ED CONTR CONTROL OL

Fig. 39 Key Cylinder—Rear View 1 2 3 4 5

– – – – –

IGNITION KEY LOCK IGNITION LOCK CYLINDE CYLINDER R PUSH PU SH PI PIN N RETAININ RET AINING G PIN SLOT SLOT RETAININ RET AINING G PIN PIN DRIV DR IVER ER

Fig. 38 Flag in RUN Position 1 – REAR OF IGNITION IGNITION SWITCH SWITCH 2 – PARK LOCK LOCK DOWEL DOWEL PIN PIN (RUN POSITION) 3 – FLAG (RUN POSITION)

(2) With key into ignition key cylinder, rotate key clo locckwis kwisee unt il retaining pin can be depress depressed ed (Fig. 39) or (Fig. 40). (3 ) I n s t a ll ll k e y cy li li n de de r i n t o i gn gn i t io ion s w it it ch ch b y a l ig ig n in in g r e t a in in i n g p in in i n t o r e t a i n in in g p in in s lo lot (F i g. g. 40).. P ush key cyli 40) cylinder nder into switch switch unt il retaining pin e n ga ga g es es . A ft ft e r p in in e n ga ga g es es , r ot ot a t e k e y t o O F F or LOCK position.

Fig. 40 Installing Key Cylinder Into Switch 1 2 3 4 5

– – – – –

IGNITION IGNITIO N SWITCH SWITCH DRIV DR IVER ER IGNITION IGNITIO N KEY LOCK LOCK CYLINDE CYLINDER R RETAININ RET AINING G PIN PIN RETAININ RET AINING G PIN SLOT SLOT

(4) Check for prop proper er retentio retention n of key cyl ylinder inder by attempting to pu ll cyli cylinder nder from swi switch. tch. (5)) Automatic Tra (5 Tra nsmissio nsmission n Only: Bef Before ore att aching ignition switch to steering column, the transmission

8D - 20


DN

REMOVAL REMOV AL AND INSTALL INSTALLA ATION (Co (Continued) ntinued) s h if ift e r m u s t b e in PAR K p os os it it io i on . T h e p a r k lock dowel do wel pin on rear of ignitio ignition n swi switch tch (Fig. 41) must also be properly properly indexed indexed into the park lo locck li linkage nkage (Fig. 42) before installing switch.

Fig. 43 Steering Wheel Lock Lever

Fig. 41 Ignition Switch View From Column 1 – REAR OF IGNITION IGNITION SWITCH SWITCH 2 – PARK LOCK LOCK DOWEL DOWEL PIN PIN (LOCK POSITION) 3 – FLAG (LOCK POSITION)

Fig. 42 Park Lock Linkage—Automatic Transmission—Typical 1 2 3 4 5

– – – – –

DOWEL LOCATING DOWEL LOCATING HOLES HOLES (2) PARK LOCK LOCK SLIDER SLIDER LINKAGE LINKAGE IGNITION IGNITI ON SWITCH SWITCH MOUNTING MOUNTING PAD PAD STEERING STEE RING COLUM COLUMN N SLOT

(6 ) T h e fl a g a t r e a r of i gn gn i t io ion s w it it ch ch (F i g. g. 4 1) 1) must be properly indexed into steering column before i n st st a l li li n g s w it it ch ch . T h is is fl a g i s u s e d t o op e r a t e t h e steering wheel lock lock lev lever er in steering col olum um n (Fig (Fig.. 43).

1 – STEE STEERING RING COLU COLUMN MN 2 – STEERING STEERING WHEEL WHEEL LOCK LOCK LEVER LEVER 3 – LOC LOCA ATOR (SHAFT AT END OF FLAG)

This lever allows steering wheel position to be locked when key switch is in LOCK position. (7) Place Place ig ignitio nition n swi switch tch in LOCK po positi sitio on. The s w it it ch ch i s i n t h e L OC OC K p os os it it i on on w h e n col u m n l oc ock flag is parallel to ignition switch terminals (Fig. 41). (8) Automatic Automatic Tran smiss smissio ion n Only Only:: Appl pply y a li light ght coa t i n g o f g r e a se se t o p a r k l oc ock d ow ow el el p in in a n d p a r k lock slider linkage. Before installing switch, push the park lock slider linkage (Fig. 42) forward until it bott om om s . D o a fi n a l p os os it it i on on i n g b y p u ll ll in in g i t r e a r w a r d about abo ut onene-quarter quarter inc inch. h. (9) Appl pply y a li light ght coating of grease to bo both th column lock flag and shaft at end of flag. (10) (1 0) Place ignition ignition switch into openings on steering column. (a) Automatic Transmissio Transmission Only Only:: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage (Fig. 42). (b) Be sure flag on rear of switch switch is positio positioned ned above steering wheel lock lever (Fig. 43). (c) Align dowel pins on rear of switch into holes on side of steering column. (d ) I n s t a ll ll 3 i gn gn i t io ion s w it it ch ch m ou ou n t i n g s cr cr e ws ws . Tighten screws to 2 N·m Ϯ.5 N·m (17 in. lbs. Ϯ 5 in. lbs.) torque. (e) After After install installing ing ig ignitio nition n swi switch, tch, rotate ig igninit i on on k e y fr om om L OC OC K t o O N p os os it it i on on . Ve r if ify t h a t park lock slider moves in slider slot, allowing gearshift lever to be moved out of PARK (auto. trans. only). If slider does not move, and gearshift lever is l oc ock e d i n P AR AR K, K, t h e i gn gn i t io ion s w it it ch ch p a r k l oc ock dowel do wel pin, on rear of ignitio ignition n swi switch, tch, is not prop prop--

DN


8D - 21

REMOVAL REMOV AL AND INSTALL INSTALLA ATION (Co (Continued) ntinued) erly installed installed in slo slott of park lo locck sli slider der li linkage. nkage. Remove ignition switch and reinstall. (11 ) C on on n e ct ct e le le ct ct r i ca ca l con n e ct ct or or s t o i gn gn i t io ion switch, swi tch, h alo lamp and (if equipped equipped ), to “PRNDL” PRNDL”.. Make sure that switch locking tabs are fully seated in wiring connectors. (1 2) 2) I n s t a ll ll s t e er er i n g col u m n cov er er s (s h r ou ou d s ). ). Tighten screws to 2 N·m (17 in. lbs.) torque. (13) Install tilt column lever (if equipped). (14) Connect negative cable to battery. (15) Check for proper operation of halo light. (16) Automat ic Tran Tran smissio smission n Only: Shifter Shifter should lock in PARK position when key is in LOCK position (if equipped equipped with shif shiftt lo locck dev devic ice) e).. Shif Shifter ter shoul should d unlock when key rotated to ON position. (17) Ch ec eck k for pr oper ope operat rat io ion n of ignitio ignition n switc switch h in ACCESSORY, LOCK, OFF, ON, RUN, an d STA START RT positions. (1 8) 8) S t e er er i n g w h e el el s h ou ou l d l oc ock w h e n k e y i s i n LOCK position. Rotate steering wheel at least 180° to v er er i fy fy. S t e er er i n g w h ee ee l s h ou ou l d u n l oc ock w h e n k e y i s rotated to ON position.

SPECIFICATIONS IGNITION TIMING Ignition timing is not adjustable on any engine.

ENGINE FIRING ORDE ORDER— R— 5. 2L/5. 9L V-8 ENGINES

COLUMN SHIFT INTERLOCK REMOVAL/INSTALLATION T h e colu m n s h if ift in t e r lo lock is u s ed ed t o lock t h e t r a n s m i s si si on on s h i ft ft e r i n t h e P a r k p os os it it i on on w h e n t h e k e y i s i n t h e O ff ff p os os it it i on on . T h e i n t er er l oc ock d e vi vi ce ce i s loccated wi lo within thin the steeri steering ng column assembl assembly y an d is not serv servic iceabl eable. e. If repair is n ec ecessary essary,, the steeri steering ng column assembl assembly y m ust be r epl eplace aced. d. Refer Refer to Group 19, Steering for procedures.

ENGINE FIRING FIRING ORDER— ORDER— 4. 7L V-8 ENGINE

8D - 22


DN

SPECIFICA SPEC IFICATIONS TIONS (Co (Continued) ntinued)

SPARK SPA RK PLUGS ENGINE

PLUG TYPE

ELECTRODE GAP

3.9L V-6

RC12LC4

1.01 mm (.040 in.)

4.7L V-8

RC12MCC4

1.01 mm (.040 in.)

5.2L V-8

RC12LC4

1.01 mm (.040 in.)

5.9L V-8

RC12LC4

1.01 mm (.040 in.)

SPARK PLUG CABLE RESISTANCE MINIMUM

MAXIMUM

250 Ohms Per Inch

1000 Ohms Per Inch

3000 Ohms Per Foot

12,000 Ohms Per Foot

IGNITION CO COIL IL RE RESIST SISTANC ANCE E— EXCE XCEPT PT 4. 7L ENGINE COIL MANUFACTURER

PRIMARY RESISTANCE @ 21-27°C (70-80°F)

SECONDARY RESISTANCE RESISTANCE @ 21-27°C (70-80°F)

Diamond

0.97 - 1.18 Ohms

11,300 - 15,300 Ohms

Toyodenso

0.95 - 1.20 Ohms

11,300 - 13,300 Ohms

IGNITION COIL COIL RESISTANC RESISTANCE E— 4. 7L V-8 ENGINE PRIMARY RESISTANCE 21-27°C (70-80°F)

SECONDARY RESISTANCE 21-27° 21-27°C C (70-80°F)

0.6 - 0.9 Ohms

6,000 - 9,000 Ohms

TORQUE CHART D E S CR IP TI ON TOR Q U E Camshaft Position Sensor Bolt— Bo lt—4.7L 4.7L V-8 En gi gine ne . . . . 12 N·m (106 (106 in. lbs.) lbs.) Crankshaft Position Sensor— 3.9L//5.2L/ 3.9L 5.2L/5.9L 5.9L Engines . . . . . . 8 N·m (70 in. lbs.) Crankshaft Position Sensor Bolt— Bo lt—4.7L 4.7L VV-8 E ngine . . . . . . 28 N·m (21 ft. lbs.) Distributor Hold Dow Down n Bolt Bolt . . . 23 N·m (17 (17 ft. ft. lbs.) lbs.) Ignition Coil Mounting (except 4.7L) (if tapped bolts bolts are u sed) . . . . 5 N·m (50 in. in. lbs.) lbs.) Ignition Coil Mounting (except 4.7L) (if nut s/ s/bo bolts lts are u sed) . . . . 11 N·m (100 (100 in. lbs.) lbs.) Ignition Coil Mounting Nut—4.7L Nut—4. 7L VV-8 Engine . . . . . . 8 N·m (70 in. in. lbs.) lbs.) Spark Plugs— Plugs—Exc Except ept 4.7L . . . . . . . . . . . 35– 35–41 41 N·m (26–30 ft. lbs.) Spark Plugs— Plugs—4. 4.7L 7L VV-8 En gi gine ne . . . . . . . . . . 27 N·m (20 ft. lbs.)

08D Ignition System

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