chrysler dakota part10

7/28/2019 chrysler dakota part10

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IGNITION SYSTEMS

CONTENTS

page page

COMPONENTIDENTIFICATION/SYSTEMOPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

COMPONENT REMOVAL/INSTALLATION . . . . . . 18

DIAGNOSTICS/SERVICE PROCEDURES . . . . . . . 6IGNITIONSWITCH . . . . . . . . . . . . . . . . . . . . . . . 27SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 29

COMPONENT IDENTIFICATION/SYSTEM OPERATION

INDEX

page page

Automatic Shutdown (ASD) Relay . . . . . . . . . . . . . . 1Camshaft Position Sensor3.9L/5.2L Engine . . . . . 2Crankshaft Position Sensor3.9L/5.2L Engine . . . . . 2Distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Engine Coolant Temperature Sensor . . . . . . . . . . . . 4General Information . . . . . . . . . . . . . . . . . . . . . . . . 1Hall Effect Pick-Up2.5L Engine . . . . . . . . . . . . . . . 4Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Intake Manifold Air Temperature Sensor3.9L/5.2LEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Manifold Absolute Pressure (MAP) Sensor . . . . . . . . 5Oxygen (O2S) Sensor . . . . . . . . . . . . . . . . . . . . . . . 5Powertrain Control Module (PCM) . . . . . . . . . . . . . . 5Throttle Body Temperature Sensor2.5L Engine . . . 5Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . 5

GENERAL INFORMATIONThroughout this group, references are made to par-

ticular vehicle models by alphabetical designation or

by the parti cular vehicle nameplate. A chart showing

a breakdown of alphabetical designations is included

in the I ntroduction group at the beginning of thismanual.

This section of the group, Component I dentifica-

tion/System Operation, will discuss ignition system

operation and will identify ignition system compo-

nents.

For diagnostic procedures and adjustments, refer to

the Diagnostics/Service Procedures section of this

group.

For removal and installation of ignition system

components, refer to the Component Removal/I nstal-

lation section of this group.

For other useful information, refer to On-Board Di-agnostics i n the General Diagnosis sections of Group

14, Fuel System in this manual.

For operation of the DRB Scan Tool, refer to the

appropriate Powertrain Diagnostic Pr ocedures ser-

vice manual.

An I gnition specifi cations section i s included at the

end of this group. A general Maintenance Schedule

(mileage intervals) for ignition related items can be

found in Group 0, Lubrication and Maintenance. This

schedule can also be found in the Owners Manual.

IGNITION SYSTEMS

Two different ignition operating systems are used.

One system is used on the 2.5L 4-cylinder engine.

The other is used on the 3.9L V-6 and 5.2L V-8 en-

gine. Similarities and differences between the two

systems will be discussed.A single-port, fuel injection system is used on the

2.5L 4-cylinder engine.

A multi-port, fuel injection system is used on the

3.9L /5.2L engine.

The ignition system is controlled by the powertraincontrol module (PCM) on all engines. The PCM wasformerly referred to as the SBE C or engine control-ler.

The ignition system consists of: Spark Plugs Ignition Coil Secondary I gnition Cables Distributor2.5L engine. Contains rotor and halleffect switch Distributor3.9L/5.2L engine. Contains rotor andcamshaft position sensor Powertrain Control Module (PCM) Crankshaft Position Sensor3.9L/5.2L engine only

AUTOMATIC SHUTDOWN (ASD) RELAYThe automatic shutdown (ASD) relay is located in

the power distribution center (PDC). The P DC is lo-cated in the engine compartment (Fig. 1). As one ofits functions, the ASD relay will supply battery volt-

IGNITION SYSTEMS 8D - 1


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age to the ignition coil. The ground circuit for the

ASD relay is controlled by the powertrain control

module (PCM ). T he PCM regulates ASD relay opera-

tion by switching the ground circuit on-and-off.

CAMSHAFT POSITIONSENSOR3.9L/5.2L

ENGINEThe camshaft position sensor is located in the dis-

tributor (Fig. 2) on all 3.9L /5.2L engines.

The camshaft position sensor contains a hall effect

device called a sync signal generator to generate afuel sync signal. This sync signal generator detects a

rotating pulse ring (shutter) on the distributor shaft.

The pulse r ing rotates 180 degrees through the sync

signal generator. I ts signal is used in conjunction

with the crankshaft position sensor to differentiate

between fuel injection and spark events. I t is also

used to synchronize the fuel injectors with their re-

spective cylinders.

When the l eading 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 i n a sync signal of approxi-

mately 5 volts.

When the trailing edge of the pulse ring (shutter)

leaves the sync signal generator, the foll owing occurs:

The change of the magnetic field causes the sync sig-

nal voltage to switch low to 0 volts.

For component testing, r efer to the Diagnostics/Ser-vice Procedures section of this group.

For removal and installation of this component, re-

fer to the Component Removal/Installation section of

this group.

CRANKSHAFTPOSITION SENSOR3.9L/5.2L

ENGINEOn the 3.9L /5.2L engines, the sensor is bolted to

the top of cylinder block near the rear of the right

cylinder head (Fig. 3).

Engine speed and crankshaft position are provided

through the crankshaft position sensor. The sensor

generates pulses that are the i nput sent to the pow-

ertrain control module (PCM). T he PCM interpretsthe sensor input to determine the crankshaft posi-

tion. The PCM then uses this position, along with

other inputs, to determine injector sequence and ig-

nition timing.

The sensor is a hall effect device combined with an

internal magnet. I t is also sensitive to steel within a

certain distance from it.

Fig. 1 Power Distribution CenterTypical

Fig. 2 Camshaft Position Sensor3.9L/5.2L Engine

Fig. 3 Crankshaft Position Sensor3.9L/5.2L Engine

8D - 2 IGNITION SYSTEMS


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SENSOR OPERATION3.9L ENGINE

The flywheel/drive plate has groups of notches at its

outer edge. On 3.9L V-6 engines, there are three sets of

double notches and three sets of single notches (Fig. 4).

The notches cause a pulse to be generated when

they pass under the sensor. The pulses are the input

to the PCM.

The engine will not operate if the PCM does not re-ceive a crankshaft position sensor input.

For component testing, refer to the Diagnostics/Ser-

vice Procedures section of this group.

For removal and installation of this sensor, refer to

the Component Removal/Installation section of this

group.

SENSOR OPERATION5.2L ENGINE

On 5.2L engines, the flywheel/drive plate has 8 sin-

gle notches, spaced every 45 degrees, at its outer

edge (Fig. 5).

The notches cause a pulse to be generated when

they pass under the sensor. The pulses are the input

to the PCM. For each engine r evolution, there are 8

pulses generated on 5.2L V-8 engines.The engine will not operate if the PCM does not re-

ceive a crankshaft position sensor input.For component testing, refer to the Diagnostics/Ser-

vice Procedures section of this group.For removal and installation of this component, re-

fer to the Component Removal/I nstallation section ofthis group.

DISTRIBUTORSFor component testing, refer to the Diagnostics/Ser-



fer to the Component Removal/Installation section of

this group.

2.5L ENGINE

The 2.5L 4-cylinder engine is equipped with a me-

chanical distributor containing a shaft driven distrib-

utor rotor. I t is driven by the timing belt through an

intermediate shaft.

The distributor uses a hall effect pick-up (Fig. 6).This supplies engine piston position and rpm infor-

mation to the powertrain control module (PCM). Re-

fer to Hall Effect Pick-Up in this section for

additional information.Fig. 4 Sensor Operation3.9L Engine

Fig. 5 Sensor Operation5.2L Engine

Fig. 6 Distributor2.5L Engine



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3.9L/5.2L ENGINES

All 3.9L V-6 and 5.2L V-8 engines are equipped

with a camshaft driven mechanical distributor, con-

taining a shaft driven distributor rotor. They are

equipped with an internal camshaft position (fuel

sync) sensor. This sensor provides fuel injection syn-

chronization and cyli nder identification.

The distributors on the 3.9L /5.2L engines do nothave built in centri fugal or vacuum assisted advance.

Base ignition timing and all timing advance is con-

trolled by the powertrain control module (PCM). Be-

cause ignition timing is controlled by the PCM, base

ignition timing is not adjustable on any of these

engines.

The distributor is held to the engine in the conven-

tional method using a holddown clamp and bolt. Al-

though the distributor on the 3.9L/5.2L engine

can be rotated, it will have no effect on ignition

timing.

All distributors contain an internal oil seal thatprevents oil from entering the distributor housing.

The seal is not serviceable.


fer to the Component Removal/I nstallation section of

this group.

IGNITIONCOILBattery voltage is supplied to the ignition coil pos-

itive terminal from the ASD relay.

The powertrain control module (PCM) opens and

closes the ignition coil ground circuit for ignition coil

operation.

Base ignition timing is not adjustable on the

3.9L/5.2L engine. By controlling the coil ground cir-

cuit, the PCM is able to set the base timing and ad-

just the ignition timing 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. T his provides heat

and vibration resistance that allows the i gnition coil

to be mounted on the engine.

2.5L engine: The coil is mounted on a bracket, to

the thermostat housing, in front of the coolant tem-

perature sensor (Fig. 7).

3.9L or 5.2L engines: T he coil is mounted to abracket that is bolted to the front of the right engine

cylinder head (F ig. 8). This bracket is also used to

mount the automatic belt tensioner.

For component testing, refer to the Diagnostics/Ser-



fer to the Component Removal/I nstallation section of

this group.

ENGINECOOLANTTEMPERATURE SENSORFor an operational description, diagnosis and re-

moval/installation procedures, refer to Group 14,

F uel System.

HALL EFFECT PICK-UP2.5L ENGINEThe distributor uses a hall effect pick-up (Fig. 9).

This supplies engine piston position and rpm infor-

mation to the powertrain control module (PCM).

A shutter (sometimes referred to as an interrupter)

is attached to the distributor shaft. This shutter con-

tains one blade per engine cylinder. A switch plate i s

mounted to the distributor housing above the shutter.The switch plate contains the distributor pick-up (ahall effect device and magnet) through which theshutter blades rotate. As the shutter blades pass

Fig. 7 Ignition Coil2.5L Engine

Fig. 8 Ignition Coil3.9L/5.2L Engines



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through the pick-up, they interrupt the magnetic

field. The hall effect device in the pick-up senses the

change in the magnetic fi eld. I t then switches on and

off, which creates pulses generating the input signal

to the PCM. The PCM calculates engine speed

through the number of pulses generated.

THROTTLE BODY TEMPERATURE SENSOR2.5L

ENGINE

For an operational description, diagnosis and re-

moval/installation procedures, refer to the 2.5L En-

gine sections of Group 14, Fuel System.

INTAKE MANIFOLD AIR TEMPERATURE SENSOR

3.9L/5.2L ENGINEFor an operational description, diagnosis and re-

moval/installation procedures, refer to the 3.9L/5.2L

Engine sections of Group 14, F uel System.

MANIFOLD ABSOLUTE PRESSURE(MAP) SENSORFor an operational description, diagnosis and re-

moval/installation procedures, refer to Group 14,Fuel System.

POWERTRAIN CONTROL MODULE (PCM)The PCM (formerly called the SBE C or engine con-

troller) is located on the right inner fender in the en-

gine compartment (Fig. 10).

The ignition system is controlled by the P CM.3.9L/5.2L Engines: Base ignition timing by ro-

tation of distributor is not adjustable.

The PCM opens and closes the ignition coil groundcircuit to operate the ignition coil. This is done to ad-just ignition timing, both initial (base) and advance,for changing engine operating conditions.

The amount of electronic spark advance providedby the PCM is determined by five input factors: cool-ant temperature, engine rpm, intake manifold tem-perature (3.9L/5.2L ) or throttle body air temperature(2.5L ), manifold absolute pressure and throttle posi-tion.

For removal and installation of this component, re-fer to the Component Removal/Installation section ofthis group.

For diagnostics, refer to the appropriate PowertrainDiagnostic Procedures service manual for operationof the DRB scan tool.

THROTTLE POSITIONSENSORFor an operational description, diagnosis and re-

moval/installation procedures, refer to Group 14,F uel System.

OXYGEN (O2S) SENSORFor an operational description, diagnosis and re-


F uel System.

Fig. 9 Hall Effect Pick-Up2.5L Engine

Fig. 10 PCM LocationTypical



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DIAGNOSTICS/SERVICE PROCEDURES

INDEX

page page

Automatic Shutdown (ASD) Relay Test . . . . . . . . . . 6Camshaft Position Sensor Test . . . . . . . . . . . . . . . . 6Crankshaft Position Sensor Test . . . . . . . . . . . . . . . 7Distributor Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Distributor Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . 7DRB Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Engine Coolant Temperature Sensor Test . . . . . . . . 8General Information . . . . . . . . . . . . . . . . . . . . . . . . 6Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Ignition Secondary Circuit Diagnosis . . . . . . . . . . . . 9

Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Intake Manifold Air Temperature Sensor Test . . . . . 12Manifold Absolute Pressure (MAP) Sensor Test . . . 12On-Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . 16Oxygen Sensor (O2S) Tests . . . . . . . . . . . . . . . . . 16Powertrain Control Module (PCM) . . . . . . . . . . . . . 12Spark Plug Secondary Cables . . . . . . . . . . . . . . . . 15Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Throttle Position Sensor Test . . . . . . . . . . . . . . . . . 16

GENERAL INFORMATIONThis section of the group, Diagnostics/Service Pro-

cedures, wil l discuss basic igniti on system diagnostics

and service adjustments.For system operati on and component i dentification,

refer to the Component I dentification/System Opera-tion section of this group.

For removal or installation of ignition system com-ponents, refer to the Component Removal/Installa-tion section of this group.

For other useful information, refer to On-Board Di-agnostics i n the General Diagnosis sections of Group14, Fuel System in this manual.

For operation of the DRB Scan Tool, refer to theappropriate Powertrain Diagnostic Pr ocedures ser-vice manual.

AUTOMATIC SHUTDOWN (ASD) RELAY TESTRefer to RelaysOperation/Testing in the Group

14, Fuel System section of this service manual.

CAMSHAFT POSITIONSENSOR TEST

3.9L/5.2L ENGINE

The camshaft position sensor is located in the dis-tri butor on all 3.9L/5.2L engines.

To perform a complete test of this sensor and itscircuitry, refer to the DRB scan tool. Also refer to theappropriate Powertrain Diagnostics Procedures man-

ual. To test the sensor only, refer to the following:For this test, an analog voltmeter is needed.

Do not remove the distributor connector from the dis-tributor. Using small paper clips, insert them intothe backside of the distributor wire harness connec-tor to make contact with the terminals. Be sure thatthe connector is not damaged when inserti ng the pa-per clips. Attach voltmeter leads to these paper clips.

(1) Connect the positive (+) voltmeter lead into thesensor output wire. This is at done the distributorwire harness connector. For wire identification, referto Group 8W, Wiring Diagrams.

(2) Connect the negative (-) voltmeter lead into theground wire. F or wire identification, refer to Group8W, Wiring Diagrams.

(3) Set the voltmeter to the 15 Volt DC scale.(4) Remove distributor cap from distributor (two

screws). Rotate (crank) the engine until the distribu-tor rotor is pointed towards the r ear of vehicle. T hemovable pulse ring should now be within the sensorpickup.

(5) Turn ignition key to ON position. Voltmetershould read approximately 5.0 volts.

(6) I f voltage is not present, check the voltmeterleads for a good connection.

(7) I f voltage is still not present, check for voltageat the supply wire. For wire i dentification, refer toGroup 8W, Wiring Diagrams.

(8) I f voltage is not present at supply wire, checkfor voltage at pin-7 of powertrain control module(PCM) 60-way connector. L eave the PCM connectorconnected for this test.

(9) I f voltage is still not present, perform vehicletest using the DRB scan tool.

(10) I f voltage is present at pin-7, but not at thesupply wire:

(a) Check continuity between the supply wire.This is checked between the distributor connectorand pin-7 at the PCM. If continuity is not present,repair the harness as necessary.

(b) Check for continuity between the camshaft

position sensor output wire and pin-44 at the PCM.I f continuity is not present, repair the harness asnecessary.

(c) Check for continui ty between the ground cir-cuit wire at the distributor connector and ground.I f continuity is not present, repair the harness asnecessary.(11) While observing the voltmeter, crank the en-

gine with ignition switch. The voltmeter needleshould fluctuate between 0 and 5 volts while the en-gine is cranking. This verifies that the camshaft po-sition sensor in the distributor is operating properly



7/32

and a sync pulse signal is being generated.

I f sync pulse signal is not present, replacement of

the camshaft position sensor is necessary.

For removal or installation of ignition system com-

ponents, refer to the Component Removal/Installa-

tion section of this group.

For system operati on and component i dentification,

refer to the Component I dentification/System Opera-tion section of this group.

CRANKSHAFT POSITIONSENSOR TESTTo perform a complete test of this sensor and its

circuitry, refer to the DRB scan tool. Also refer to theappropriate Powertrain Diagnostics Procedures man-ual. To test the sensor only, refer to the following:

On the 3.9L /5.2L engine, the sensor is located onthe top of cylinder block near the rear of right cylin-der head (Fig. 1).

(1) Near the rear of intake manifold, disconnectsensor pigtail harness connector from main wiring

harness.

(2) Pl ace an ohmmeter across terminals B and C(Fig. 2). Ohmmeter should be set to 1K -to-10K scalefor this test. The meter reading should be open (noresistance). Replace sensor if a low resistance is i ndi-cated.

DISTRIBUTOR CAP

INSPECTION

Remove the distributor cap and wipe it clean witha dry lint free cloth. Visually inspect the cap forcracks, carbon paths, broken towers, or damaged ro-tor button (Figs. 3 and 4). Also check for white depos-

its on the inside (caused by condensation entering

the cap through cracks). Replace any cap that dis-

plays charred or eroded terminals. The inside flat

surface of a terminal end (faces toward rotor) will in-

dicate some evidence of erosion from normal opera-

tion. Examine the terminal ends for evidence of

mechanical interference with the rotor tip.

DISTRIBUTOR ROTORVisually inspect the r otor (Fig. 5) for cracks, evi-

dence of corrosion, or the effects of arcing on the

metal tip. Also check for evidence of mechanical in-

terference with the cap. Some charri ng is normal on

the end of the metal tip. The silicone-dielectric-var-

nish-compound applied to the rotor tip for radio in-

terference noise suppression, will appear charred.

This is normal. Do not remove the charred com-

pound. Test the spring for insufficient tension. Re-

place a rotor that displays any of these adverse

conditions.


Fig. 2 Typical Sensor Connector

Fig. 3 Cap InspectionExternalTypical



8/32

DRBSCAN TOOLFor operation of the DRB scan tool, refer to the ap-

propriate P owertr ain Diagnostic Procedures service

manual.

IGNITIONCOIL

To perform a complete test of the ignition coil andits circuitry, refer to the DRB scan tool. Also refer to

the appropriate Powertrain Diagnostics Pr ocedures

manual. To test the coil only, refer to the following:

The ignition coil (Figs. 6 or 7) is designed to oper-

ate without an external ballast resistor.

I nspect the igniti on coil for arcing. Test the coil ac-

cording to coil tester manufacturers instructions.

Test the coil primary and secondary resistance. Re-

place any coil that does not meet specifications. Refer

to the I gnition Coil Resistance chart.

I f the ignition coil is being replaced, the secondary

spark plug cable must also be checked. Replace cable

if it has been burned or damaged.

Arcing at the tower will carbonize the cable boot,

which if it is connected to a new ignition coil, willcause the coil to fail.

I f the secondary coil cable shows any signs of dam-

age, it should be replaced with a new cable and new

terminal. Carbon tracking on the old cable can cause

arcing and the failure of a new ignition coil.

ENGINECOOLANTTEMPERATURE SENSOR TESTFor an operational description, diagnosis and re-


F uel System.

Fig. 4 Cap InspectionInternalTypical

Fig. 5 Rotor InspectionTypical

Fig. 6 Ignition Coil2.5L EngineTypical

Fig. 7 Ignition Coil3.9L/5.2L EngineTypical



9/32

IGNITIONSECONDARYCIRCUIT DIAGNOSIS

CHECKING FOR SPARK

CAUTION: When disconnecting a high voltage cable

from a spark plug or from the distributor cap, twist

the rubber boot slightly (1/2 turn) to break it loose

(Fig. 8). Grasp the boot (not the cable) and pull itoff with a steady, even force.

CAUTION: Do not pull spark plug cables from dis-

tributor cap of a 2.5L engine. The cables must be

released from inside the distributor cap (Fig. 9).

(1) Disconnect the ignition coil secondary cablefrom center tower of the distributor cap. Hold the ca-ble terminal approximately 12 mm (1/2 i n.) from agood engine ground (Fig. 10).

WARNING: BE VERY CAREFUL WHEN THE ENGINE

IS CRANKING. DO NOT PUT YOUR HANDS NEARTHE PULLEYS, BELTS OR THE FAN. DO NOT WEARLOOSE FITTING CLOTHING.

(2) Rotate (crank) the engine with the starter mo-tor and observe the cable terminal for a steady arc. Ifsteady arcing does not occur, inspect the secondarycoil cable. Refer to Spark Pl ug Cables in this group.

Also inspect the distributor cap and rotor for cracks

or burn marks. Repair as necessary. I f steady arcingoccurs, connect igniti on coil cable to the distributorcap.

(3) Remove a cable from one spark plug.(4) Using insulated pliers, hold the cable terminal

approximately 12 mm (1/2 in.) from the engine cylin-der head or block while r otating the engine with thestarter motor. Observe the spark plug cable terminalfor an arc. I f steady arcing occurs, it can be expected

IGNITION COIL RESISTANCE

Fig. 8 Cable Removal

Fig. 9 Spark Plug Cable Removal/Installation2.5LEngine

Fig. 10 Checking for SparkTypical



10/32

that the i gnition secondary system is operating cor-

rectly. (note that if the ignition coil cable is re-

moved for this test, instead of a spark plug

cable, the spark intensity will be much higher.)

I f steady arcing occurs at the spark plug cables, but

the engine will not start, connect the DRB scan tool.

Refer to the Powertrain Diagnostic Procedures ser-

vice manual.

FAILURE TO START TEST

To prevent unnecessary diagnostic time and wrong

test results, the previous Checking For Spark test

should be performed prior to thi s test.

WARNING: SET PARKING BRAKE OR BLOCK THE

DRIVE WHEELS BEFORE PROCEEDING WITH THIS

TEST.

(1) Unplug the i gnition coil harness connector at

the coil (Figs. 11 or 12).

(2) Connect a set of small jumper wires (18 gaugeor small er) between the disconnected harness termi-

nals and the ignition coil terminals. To determine po-

larity at connector and coil, refer to the Wiring

Diagrams section.

(3) Attach one lead of a voltmeter to the positive

(12 volt) jumper wire. Attach the negative side of

voltmeter to a good ground. Determine that sufficient

battery voltage (12.4 volts) is present for the starting

and ignition systems.

(4) Crank the engine for 5 seconds while monitor-

ing the voltage at the coil positive terminal:

I f the voltage remains near zero during the entire

period of cranking, refer to On-Board Diagnostics inGroup 14, F uel Systems. Check the powertrain con-

trol module and auto shutdown relay.

I f voltage is at or near battery voltage and drops

to zero after 1-2 seconds of cranking, check the pow-

ertrain control module circuit. Refer to On-Board Di-

agnostics in Group 14, F uel Systems.

I f voltage r emains at or near battery voltage dur-

ing the entire 5 seconds, turn the key off. Remove

the 60-way connector (Fig. 13) from the powertr ain

control module (PCM). Check 60-way connector forany spread terminals.

(5) Remove test lead from the coil positive termi-nal. Connect an 18 gauge jumper wire between the

battery positive terminal and the coil positive termi-nal.

(6) Make the special jumper shown in figure 14.Using the jumper, momentarily ground terminal-19of the 60-way connector. A spark should be generatedat the coil cable when the ground i s removed.

(7) I f spark is generated, replace the powertraincontrol module (PCM).

(8) I f spark is not seen, use the special jumper toground the coil negative terminal directly.

(9) I f spark is produced, repair wiring harness foran open condition.

Fig. 11 Coil Harness Connector2.5L EngineTypical

Fig. 12 Coil Harness Connector3.9/5.2L EngineTypical

Fig. 13 PCM 60-Way Connector



11/32

(10) I f spark is not produced, replace the ignitioncoil.

IGNITION TIMING

2.5L ENGINE

WARNING: APPLY PARKING BRAKE AND/OR

BLOCK WHEELS BEFORE PERFORMING IGNITIONTIMING ADJUSTMENT, OR ANY TESTS WITH A

RUNNING ENGINE.

Proper ignition timing is required to obtain opti-mum engine performance. The distributor must becorrectly indexed to provide correct initial ignitiontiming.

(1) Set the gearshift selector in park or neutraland apply the parking brake. All lights and accesso-ries must be off.

(2) I f a magnetic timing unit is being used, i nsertthe pickup probe into the open receptacle on the

transmission bell housing. This is located next to theupper, left mounting bolt. I f a magnetic timing unitis not available, use a conventional timing light con-nected to the number one cylinder spark plug cable.Use the timing scale on the transmission dust cover(Fig. 15).

Do not puncture cables or boots with testprobes. Always use proper adapters. Puncturi ng thespark plug cables with a probe will damage the ca-bles. T he probe can separate the conductor and cause

high resistance. I n addition, breaking the rubber in-

sulation may permit secondary current to arc to

ground.

(3) Turn selector switch to the appropriate cylinder

position.

(4) Start engine and run until normal operating

temperature is obtained.

(a) I f using the DRB scan tool: Connect the DRBtool. Refer to the appropriate Powertr ain Diagnos-

tic Procedures service manual.(b) I f not using the DRB tool: Disconnect the

coolant temperature sensor (Fig. 16). When thesensor is disconnected, the radiator (electrical) cool-ing fan should operate and the malfunction indica-tor lamp (displayed on the instrument panel as theCHE CK EN GIN E lampfigure 17) should be lit.

(5) Aim timing light at timing scale (Fig. 15) onthe transmission dust cover, or read magnetic timingunit. I f flash occurs when timing mark is before spec-ified degree mark, timing is advanced. To adjust,turn distributor housing in direction of rotor rotation.

I f flash occurs when timing mark is after specified

degree mark, timing is retarded. To adjust, turn dis-tributor housing against direction of rotor rotation.Refer to Vehicle E mission Control I nformation label(under vehicle hood) for correct timing specification.If timing is within 2 degrees of value specifi ed onthe l abel, proceed to step (7). I f outside specifi ed tol-erance, proceed to next step.

(6) L oosen distributor hold-down arm screw justenough so the distributor housing can be rotated(Fig. 18). Turn distributor housing until specifiedtiming is reached. Tighten the hold-down arm screwand recheck timing.

Fig. 14 Special Jumper Ground-to-Coil NegativeTerminal

Fig. 15 Timing Marks2.5L Engine

Fig. 16 Coolant Temperature Sensor2.5L Engine



12/32

(7) Turn the engine off. Remove ti ming light or

magnetic timing unit and tachometer. I f the coolant

temperature sensor was disconnected, connect the

sensor and erase the diagnostic trouble codes using

the Erase Diagnostic Trouble Code mode on the DRB

scan tool. Refer to the appropriate P owertrain Diag-

nostic Procedures service manual.

3.9L/5.2L ENGINE

Base (initial) ignition timing is NOT adjust-

able on any 3.9L/5.2L engine. Do not attempt to

adjust ignition timing by rotating the distribu-

tor.

All ignition ti ming functions are controlled by the

powertr ain control module (PCM). Refer to On-Board

Diagnostics in the M ulti-Port Fuel I njectionGen-

eral Diagnosis section of Group 14, F uel Systems for

more information. Also refer to the appropriate Pow-

ertr ain Diagnostics Procedures service manual for op-

eration of the DRB Scan Tool.

INTAKE MANIFOLD AIR TEMPERATURE SENSOR

TESTFor an operational description, diagnosis or remov-

al/ installation procedures, refer to Group 14, Fuel

Systems.

MANIFOLD ABSOLUTE PRESSURE(MAP) SENSOR

TESTFor an operational description, diagnosis and re-


F uel System.

POWERTRAIN CONTROL MODULE (PCM)The PCM (formerly called the SBE C or engine con-

troller) is located on the right inner fender in the en-

gine compartment (Fig. 19).

The ignition system is controlled by the P CM.

For removal and installation of this component, re-fer to the Component Removal/Installation section ofthis group.

For diagnostics, refer to the appropriate PowertrainDiagnostic Procedures service manual for operationof the DRB scan tool.

SPARKPLUGSFor spark plug removal, cleaning, gap adjustment

and installation, refer to the Component Removal/I n-

stallation section of this group.3.9L/5.2L Engine: Spark plug cable boot heat

shields are pressed into the cylinder head to sur-round each cable boot and spark plug (Fig. 20). Theseshields protect the spark plug boots from damage(due to intense engine heat generated by the exhaustmanifolds) and should not be removed. After thespark plug cable has been installed, the lip of the ca-ble boot should have a small air gap to the top of theheat shield (Fig. 20).

Faulty carbon and/or gas fouled plugs generallycause hard starting, but they will clean up at higher

Fig. 17 Check Engine LampTypical

Fig. 18 Distributor Holddown2.5L Engine

Fig. 19 PCM Location



13/32

engine speeds. Faulty plugs can be identified in a

number of ways: poor fuel economy, power loss, de-

crease in engine speed, hard starting and, in general,

poor engine performance.

Remove the spark plugs and examine them for

burned electrodes and fouled, cracked or broken por-

celain insulators. K eep plugs arranged in the order

in which they were removed from the engine. An iso-

lated plug displaying an abnormal condition indicates

that a problem exists in the corresponding cylinder.

Replace spark plugs at the intervals recommended in

the maintenance chart in Group 0, L ubrication and

Maintenance.

Spark plugs that have low mileage may be cleaned

and reused if not otherwise defective. Refer to the

following Spark Pl ug Condition section of this group.

CONDITION

NORMAL OPERATING

The few deposits present on the spark plug will

probably be light tan or slightly gray in color. This is

evident with most grades of commercial gasoline

(Fig. 21). There will not be evidence of electrode

burning. Gap growth will not average more than ap-

proximately 0.025 mm (.001 in) per 1600 km (1000

miles) of operation. Spark plugs that have normal

wear can usually be cleaned, have the electrodesfiled, have the gap set and then be installed.

Some fuel refiners in several areas of the U nited

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

with a rust colored deposit. This rust color can be

misdiagnosed as being caused by coolant in the com-

bustion chamber. Spark plug performance is not af-

fected by M MT deposits.

COLDFOULING/CARBONFOULING

Cold fouling is sometimes referred to as carbon

fouling. The deposits that cause cold fouling are ba-sically carbon (Fi g. 21). A dry, black deposit on one or

two plugs in a set may be caused by sticking valves

or defective spark plug cables. Cold (carbon) fouling

of the entire set of spark plugs may be caused by aclogged air cleaner element or repeated short operat-ing times (short trips).

WET FOULING OR GAS FOULING

A spark plug coated with excessive wet fuel or oil iswet fouled. I n older engines, worn piston rings, leak-ing valve guide seals or excessive cylinder wear cancause wet fouling. I n new or recently overhauled en-

gines, wet fouling may occur before break-in (normaloil control) is achieved. This condition can usually beresolved by cleaning and reinstalli ng the fouledplugs.

OIL OR ASHENCRUSTED

I f one or more spark plugs are oil or oil ash en-crusted (Fig. 22), evaluate engine condition for thecause of oil entry into that particular combustionchamber.

ELECTRODEGAP BRIDGING

Electrode gap bridging may be traced to loose de-

posits in the combustion chamber. These deposits ac-cumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenlysubjected to a high torque load, deposits partially liq-uefy and bridge the gap between electrodes (Fig. 23).This short circuits the electrodes. Spark plugs withelectrode gap bridging can be cleaned using standardprocedures.

SCAVENGERDEPOSITS

Fuel scavenger deposits may be either white or yel-low (Fig. 24). They may appear to be harmful, but

Fig. 20 Heat Shields3.9L/5.2L Engine Fig. 21 Normal Operation and Cold (Carbon) Fouling



14/32

this is a normal condition caused by chemical addi-

tives in certain fuels. These additives are designed to

change the chemical nature of deposits and decrease

spark plug misfire tendencies. Notice that accumula-tion on the ground electrode and shell area may be

heavy, but the deposits are easily removed. Sparkplugs with scavenger deposits can be considered nor-mal in condition and can be cleaned using standardprocedures.

CHIPPED ELECTRODE INSULATOR

A chipped electrode insulator usually results frombending the center electrode while adjusting thespark plug electrode gap. Under certain conditions,severe detonation can also separate the insulatorfrom the center electrode (Fig. 25). Spark plugs withthis condition must be replaced.

PREIGNITIONDAMAGE

Preignition damage is usually caused by excessivecombustion chamber temperature. The center elec-trode dissolves first and the ground electrode dis-solves somewhat latter (Fi g. 26). I nsulators appearrelatively deposit free. Determine i f the spark plughas the correct heat range rating for the engine. De-termine if ignition timing is over advanced, or ifother operating conditions are causing engine over-heating. (The heat range rating refers to the operat-ing temperature of a particular type spark plug.

Spark plugs are designed to operate within specifictemperature ranges. This depends upon the thick-ness and length of the center electrodes porcelain in-sulator.)

SPARKPLUGOVERHEATING

Overheating is indicated by a white or gray centerelectrode insulator that also appears blistered (Fig.27). The increase i n electrode gap will be consider-ably in excess of 0.001 inch per 1000 miles of opera-tion. This suggests that a plug with a cooler heatrange r ating should be used. Over advanced igniti on

Fig. 22 Oil or Ash Encrusted

Fig. 23 Electrode Gap Bridging

Fig. 24 Scavenger Deposits

Fig. 25 Chipped Electrode Insulator



15/32

timing, detonation and cooling system malfunctions

can also cause spark plug overheating.

SPARKPLUGSECONDARY CABLES3.9L/5.2L Engine: Spark plug heat shields are

pressed into the cylinder head to surround eachspark plug cable boot and spark plug (Fig. 28). Theseshields protect the spark plug boots from damage(due to intense engine heat generated by the exhaustmanifolds) and should not be removed. After thespark plug cable has been installed, the lip of the ca-

ble boot should have a small air gap to the top of theheat shield (Fi g. 28).

CAUTION: 2.5L 4-CYLINDER ENGINE. Do not pull

spark plug cables from distributor cap of a 2.5L en-gine. The cables must be released from inside thedistributor cap (Fig. 29).

TESTING

Spark plug cables are sometimes r eferred to as sec-ondary ignition cables or secondary wir es. T he cablestransfer electrical current from the distributor to i n-

dividual spark plugs at each cylinder. T he spark plug

cables are of nonmetallic construction and have abuilt in resistance. The cables provide suppression ofradio frequency emissions from the igniti on system.

Check the high-tension cable connections for goodcontact at the ignition coil, distributor cap towersand spark plugs. Terminals should be fully seated.The terminals and spark plug covers should be ingood condition. Terminals should fit tightly to the ig-nition coil, distributor cap and spark plugs. The

spark plug cover (boot) of the cable should fit tightaround the spark plug insulator. L oose cable connec-tions can cause corrosion and increase resistance, re-sulting in shorter cable service life.

Clean the high tension cables with a cloth moist-ened with a nonflammable solvent and wipe dry.Check for brittle or cracked insulation.

When testing secondary cables for damage with anoscilloscope, foll ow the instructions of the equipmentmanufacturer.

I f an oscilloscope is not available, spark plug cablesmay be tested as follows:

Fig. 26 Preignition Damage

Fig. 27 Spark Plug Overheating

Fig. 28 Heat Shields3.9L/5.2L Engine

Fig. 29 Spark Plug Cable Removal/Installation2.5L

Engine



16/32

CAUTION: Do not leave any one spark plug cable

disconnected for longer than necessary during test-

ing. This may cause possible heat damage 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 agood engine ground. I f the cable and spark plug arein good condition, the engine rpm should drop andthe engine will run poorly. I f engine rpm does notdrop, the cable and/or spark plug may not be operat-ing properly and should be replaced. Also check en-gine cyli nder compression.

With the engine not running, connect one end of atest probe to a good ground. Start the engine and runthe other end of the test probe along the entirelength of all spark plug cables. I f cables are crackedor punctured, there will be a noticeable spark jumpfrom the damaged area to the test probe. The cable

running from the ignition coil to the distributor capcan be checked in the same manner. Cracked, dam-aged or faulty cables should be replaced with resis-tance type cable. This can be identified by the wordsEL ECT RONIC SUPPRE SSION printed on the cablejacket.

Use an ohmmeter to test for open circuits, exces-sive resistance or loose terminals. Remove the dis-tributor cap from the distributor. Do not removecables from cap. Remove cable from spark plug.Connect ohmmeter to spark plug terminal end of ca-ble and to corresponding electrode in distributor cap.Resistance should be 250 to 1000 Ohms per inch of

cable. I f not, remove cable from distributor cap towerand connect ohmmeter to the terminal ends of cable.I f resistance is not within specifications as found i nthe Spark Pl ug Cable Resistance chart, replace thecable. Test all spark plug cables i n this manner.

To test ignition coil-to-distributor cap cable, do notremove the cable from the cap. Connect ohmmeter to

rotor button (center contact) of distributor cap and

terminal at ignition coil end of cable. I f resistance is

not within specifications as found in the Spark Pl ug

Cable Resistance chart, remove the cable from the

distributor cap. Connect the ohmmeter to the termi-

nal ends of the cable. I f resistance is not within spec-

ifications as found in the Spark Plug Cable

Resistance chart, replace the cable. I nspect the igni-tion coil tower for cracks, burns or corrosion.

For removal and installation of spark plug cables,

refer to Spark Pl ug Secondary Cables in the Compo-

nent Removal/Installation section.

THROTTLE POSITIONSENSOR TESTFor an operational description, diagnosis and re-


F uel System.

OXYGEN SENSOR (O2S) TESTS

For diagnosis, removal or installation, refer toGroup 14, Fuel Systems in this manual.

ON-BOARD DIAGNOSTICS

FOR CERTAIN IGNITION SYSTEM

COMPONENTS

The powertrain control module (PCM) performs an

On-Board Diagnostic (OBD) check for certain ignition

system components on all vehicles. This is done by

setting a diagnostic trouble code (DTC).

A DTC can be obtained in two different ways. One

of the ways is by connecting the DRB scan tool to the

data link connector. This connector is located in theengine compartment (Fig. 30). Refer to the appropri-

ate Powertrain Diagnostic Pr ocedures service manual

for operation of the DRB scan tool. The other way is

to cycle the ignition key and observe the malfunction

indicator lamp (MI L ). The M I L lamp i s displayed on

the instrument panel as the CHECK EN GIN E lamp

(Fig. 31). This lamp will flash a numeric code. I f a

numeric code number 11 (for the crankshaft position

sensor) or 42 (for the ASD relay) is observed, a prob-

lem has been found in the ignition system.

Note that the CHE CK EN GINE lamp will illumi-

nate initially for approximately two seconds eachtime the ignition key is turned to the ON position.

This is done for a bulb test.

SPARK PLUG CABLE RESISTANCE



17/32

For a complete operational description of allDTCs, for accessing a DTC and for erasing aDTC, refer to On-Board Diagnostics. This canbe found in the General Diagnosis sections of

Group 14, Fuel System. For numeric flash lamp

code charts, refer to Diagnostic Trouble Code

(DTC). This can also be found in the General

Diagnosis sections of Group 14, Fuel System.

Fig. 30 Data Link Connector LocationTypicalLocation

Fig. 31 Check Engine LampTypical Location



18/32

COMPONENT REMOVAL/INSTALLATION

INDEX

page page

Automatic Shutdown (ASD) Relay . . . . . . . . . . . . . 18Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . 18Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . 19Distributor2.5L Engine . . . . . . . . . . . . . . . . . . . . 20Distributor3.9L/5.2L Engine . . . . . . . . . . . . . . . . 21Engine Coolant Temperature Sensor . . . . . . . . . . . 20General Information . . . . . . . . . . . . . . . . . . . . . . . 18Hall Effect Pick-Up2.5L Engine . . . . . . . . . . . . . . 23

Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Intake Manifold Air Temperature Sensor . . . . . . . . . 23Manifold Absolute Pressure (MAP) Sensor . . . . . . . 24Oxygen (O2S) Sensor . . . . . . . . . . . . . . . . . . . . . . 24Powertrain Control Module (PCM) . . . . . . . . . . . . . 24Spark Plug Secondary Cables . . . . . . . . . . . . . . . . 25Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . 26

GENERAL INFORMATIONThis section of the group, Component Removal/In-

stallation, will discuss the removal and installation

of ignition system components.

For basic ignition system diagnostics and serviceadjustments, refer to the Diagnostics/Service Proce-

dures section of this group.

For system operati on and component i dentification,

refer to the Component I dentification/System Opera-

tion section of this group.

AUTOMATIC SHUTDOWN (ASD) RELAYThe ASD relay is installed in the power distribu-

tion center (PDC) (Fig. 1). Relay location is printed

on the PDC cover.

REMOVAL

(1) Remove the PDC cover.

(2) Remove the relay by li fting straight up.

INSTALLATION

(1) Push the relay into the connector.

(2) I nstall the relay cover.

CAMSHAFT POSITIONSENSORThe camshaft position sensor is located in the dis-

tributor (Fig. 2).

REMOVAL3.9L/5.2L ENGINE

Distributor removal is not necessary to removecamshaft position sensor.

(1) Disconnect negative battery cable at battery.

(2) Remove distributor cap from distributor (two

screws).

(3) Disconnect camshaft position sensor wiring

harness from main engine wiring harness.

(4) Remove distributor rotor from distributor shaft.

(5) L ift the camshaft position sensor assembly

from the distributor housing (Fig. 2).

INSTALLATION

(1) I nstall camshaft position sensor to distributor.

Al ign sensor into notch on distributor housing.

(2) Connect wiring harness.

(3) I nstall rotor.

(4) I nstall distributor cap. Tighten mounting screws.

Fig. 1 Power Distribution CenterTypical

Fig. 2 Camshaft Position Sensor3.9L/5.2L Engine



19/32

CRANKSHAFT POSITIONSENSOR


The sensor is bolted to the top of the cylinder block

near the rear of right cylinder head (Fig. 3).

(1) Remove the spark plug cable loom and spark

plug cables from valve cover mounting stud at rear of

right valve cover (Fig. 3). Position spark plug cables

to top of valve cover.

(2) Disconnect 2 hoses at Exhaust Gas Recircula-tion (EGR) valve. Note position of hoses at EGR

valve before removal.

(3) Disconnect electri cal connector and hoses at

electri c E GR valve control. Note position of hoses be-

fore removal.

(4) Remove 2 EGR valve mounting bolts and re-

move EGR valve. Discard old EGR gasket.

(5) Disconnect electrical connector at engine oil

pressure sending unit.

(6) To prevent damage to oil pressure sending unit,

a special tool, such as number C-4597 must be used

(Fig. 4). Remove sending unit from engine.(7) L oosen EGR tube mounting nut at i ntake man-

ifold.

(8) Remove 2 E GR tube mounting bolts at exhaust

manifold (Fig. 3) and remove EGR tube. Discard old

gasket at exhaust manifold.

(9) Disconnect crankshaft position sensor pigtail

harness from main wiring harness.

(10) Remove 2 sensor (recessed hex head) mount-

ing bolts (Fig. 3) and remove sensor.

INSTALLATION

(1) Position crankshaft position sensor to engine

and install mounting bolts. Tighten bolts to 8 Nm

(70 in. lbs.) torque.

(2) Connect main harness electri cal connector to

sensor.

(3) Clean the EGR tube and exhaust manifold (at

EGR tube mounting point) of any old gasket mate-

rial.(4) I nstall a new gasket to exhaust manifold end of

EGR tube and install EGR tube to both manifolds.

Tighten mounting nut at intake manifold. Tighten 2

mounting bolts at exhaust manifold to 23 Nm (204

in. lbs.) torque.

(5) Coat the threads of the oil pressure sending

unit with thread sealant. Do not allow any of the

thread sealant to get into the sending unit opening,

or the opening at the engine. I nstall sending unit to

engine and tighten to 14 Nm (130 in. l bs.) torque. I n-

stall electrical connector to sending unit.

(6) Clean the intake manifold and EGR valve ofany old gasket material.

(7) I nstall a new E GR valve gasket at intake man-

ifold.

(8) I nstall EGR valve to intake manifold. Tighten 2

bolts to 23 Nm (200 in. lbs.) torque.

(9) Position EGR valve control and install its elec-

trical connector. Connect hoses between EGR valve

and EGR valve control. Connect hose between main

vacuum harness and control valve.(10) I nstall spark plug cable loom and spark plug

cables to valve cover mounting stud.


Fig. 4 Oil Pressure Sending UnitRemoval/

Installation



20/32

ENGINE COOLANTTEMPERATURE SENSORFor an operational description, diagnosis and re-


Fuel System.

DISTRIBUTOR2.5L ENGINEAlso refer to Hall Effect Pick-Up in this section for

removal and installation.

REMOVAL

(1) Disconnect distributor pick-up l ead wire at wir-

ing harness connector (Fig. 5).

(2) Remove splash shield retaining screws (Fig. 5).(3) Remove splash shield (Fi g. 6).

(4) L oosen distributor cap retaining screws (Fig. 7).

(5) L ift off distributor cap (Fig. 8).

(6) Rotate engine crankshaft until the distributor

rotor is pointing toward the cylinder block. Use this

as a reference when installing distributor.

(7) Remove distributor holddown clamp bolt

(screw) (Fig. 9).

(8) Carefully lift the distributor from the engine.

INSTALLATION

(1) Position distributor in engine. Make certainthat the O-ring is properly seated on distributor. I f

O-ring is cracked or nicked, replace O-ri ng.

(2) Carefully engage distributor drive with auxil-

iary shaft drive. When distributor is installed prop-

erly, rotor will be pointing toward cylinder block. I f

engine has been cranked while distributor is re-

moved, i t will be necessary to establish proper rela-

tionship between the distributor shaft and number

one piston position as follows:

(a) Rotate the crankshaft until number one pis-

ton is at top of compression stroke. Pointer on

clutch housing shield should be i n line with the 0

degree (TDC) mark on flywheel.

(b) Rotate rotor to a position just ahead of the

number one distributor cap terminal.

(c) L ower the distributor into the opening, engag-

ing distributor drive with drive on auxiliary shaft.

With distributor fully seated on engine, rotorshould be aligned under the cylinder number-one

distributor cap tower.

(3) I nstall the distributor cap. Be sure all high ten-

sion cables snap firmly in the cap towers.

(4) I nstall hold-down clamp bolt (screw) and

tighten finger tight (Fig. 9).

(5) I nstall splash shield (Figs. 5 and 6).

(6) Connect distributor hall effect pick-up lead wire

at wiring harness connector.

Fig. 6 Splash Shield2.5L Engine

Fig. 7 Distributor Cap Retaining Screws2.5LEngine

Fig. 5 Pick-Up Lead Connector and Splash Shield



21/32

(7) Set ignition ti ming to specification. Refer to I g-

nition Timing in the Diagnostics/Service Pr ocedures

section of this group.

DISTRIBUTOR3.9L/5.2L ENGINE

REMOVAL

CAUTION: Base ignition timing is not adjustable on

any 3.9L V-6 or 5.2L V-8 engine. Distributors do not

have built in centrifugal or vacuum assisted ad-

vance. Base ignition timing and timing advance are

controlled by the powertrain control module (PCM).

Because a conventional timing light can not be

used to adjust distributor position after installation,

note position of distributor before removal.

(1) Disconnect negative battery cable at battery.

(2) Remove distributor cap from distributor (two

screws).

(3) Mark the position of distributor housing in

relationship to engine or dash panel. This is done

to aid in installation.

Before distributor is removed, the number-one cyl-

inder must be brought to the top dead center (TDC)

firing position.

(4) Attach a socket to the Crankshaft Vibration

Damper mounting bolt.

(5) Slowly rotate engine clockwise, as viewed from

front, until indicating mark on crankshaft vibration

damper is aligned to 0 degree (TDC) mark on timingchain cover (Fi g. 10).

(6) The distributor rotor should now be aligned tothe CY L . NO. 1 alignment mark (stamped) into thecamshaft position sensor (Fig. 11). I f not, rotate thecrankshaft through another complete 360 degreeturn. Note the position of the number-one cylinder

spark plug cable (on the cap) in relation to rotor. Ro-tor should now be aligned to this position.

(7) Disconnect camshaft position sensor wiringharness from main engine wiring harness.

(8) Remove distributor rotor from distributor shaft.(9) Remove distributor holddown clamp bolt and

clamp (F ig. 12). Remove distri butor from vehicle.

Fig. 8 Distributor Cap2.5L Engine

Fig. 9 Distributor Holddown2.5L Engine

Fig. 10 Damper-To-Cover Alignment Marks3.9L/5.2L Engine

Fig. 11 Rotor Alignment Mark3.9L/5.2L Engine



22/32

CAUTION: Do not crank engine with distributor re-

moved. Distributor/crankshaft relationship will be

lost.

INSTALLATION

I f engine has been cranked while distributor is re-

moved, establi sh the relationship between distributor

shaft and number one piston position as follows:

Rotate crankshaft in a clockwise direction, as

viewed from front, until number-one cylinder piston

is at top of compression stroke (compression should

be felt on finger with number one spark removed).

Then continue to slowly rotate engine clockwise until

indicating mark (Fig. 10) is aligned to 0 degree(TDC) mark on timing chain cover.

(1) Clean top of cylinder block for a good seal be-

tween distributor base and block.

(2) L ightly oil the rubber O-ring seal on the dis-

tri butor housing.

(3) I nstall rotor to distributor shaft.

(4) Position distributor into engine to its original

position. Engage tongue of distributor shaft with slot

in distributor oil pump drive gear. Position rotor to

the number one spark plug cable position.

(5) I nstall distributor holddown clamp and clamp

bolt. Do not tighten bolt at this time.

(6) Rotate the distributor housing until rotor is

aligned to CY L . NO. 1 alignment mark on the cam-

shaft position sensor (Fi g. 11).

(7) Tighten clamp holddown bolt (Fig. 12) to 22.5

Nm (200 in. lbs.) torque.

(8) Connect camshaft position sensor wiring har-

ness to main engine harness.

(9) I nstall distributor cap. Tighten mounting

screws.

(10) Refer to the following Checking Distributor

Position.

CHECKING DISTRIBUTOR POSITION

To verify correct distributor rotational position,

connect the DRB scan tool to the data l ink connector.

The data link connector is located in the engine com-

partment. Gain access to the SE T SYNC screen on

the DRB.

WARNING: WHEN PERFORMING THE FOLLOWINGTEST, THE ENGINE WILL BE RUNNING. BE CARE-

FUL NOT TO STAND IN LINE WITH THE FAN

BLADES OR FAN BELT. DO NOT WEAR LOOSE

CLOTHING.

Follow the directions on the DRB screen and start

the engine. With the engine running, the words I N

RAN GE should appear on the screen along with 0.

This indicates correct distributor position.I f a plus (+) or a minus (-) is displayed next to the

degree number, and/or the degree displayed is notzero, loosen but do not remove the distributor hold-

down clamp bolt. Rotate the distributor until I NRAN GE appears on the screen. Continue to rotatethe distributor until achieving as close to 0 as pos-sible. After adjustment, tighten clamp bolt to 22.5Nm (200 in. lbs.) torque.

The degree scale on the SET SYNC screen of theDRB is referring to fuel synchronization only. It isnot referring to ignition timing. Because of this,do not attempt to adjust ignition timing using thismethod. Rotating the distributor will have no effecton ignition timing. All ignition timing values are con-trolled by the powertrain control module (PCM).

IGNITIONCOILThe ignition coil is an epoxy filled type. I f the coil

is replaced, it must be replaced with the same type.

REMOVAL2.5L ENGINE

The coil is mounted on a bracket, to the thermostathousing, i n front of the coolant temperature sensor(Fig. 13).

(1) Di sconnect the ignition coil secondary cablefrom ignition coil (Fig. 13).

(2) Disconnect engine harness connector from igni-tion coil.

(3) Remove ignition coil mounting screws. Removecoil.

INSTALLATION2.5L ENGINE

(1) I nstall ignition coil to bracket on cylinder blockwith mounting screws.

(2) Connect engine harness connector to coil.(3) Connect ignition coil cable to i gnition coil.


The ignition coil is mounted to a bracket near thefront of the r ight engine cylinder head on 3.9L /5.2Lengines (Fig. 14).

Fig. 12 Distributor Holddown Clamp3.9L/5.2LEngine



23/32

(1) Disconnect the wiring and secondary cable from

the ignition coil (Fig. 14).

WARNING: DO NOT REMOVE THE COIL MOUNTING

BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS.THE COIL MOUNTING BRACKET IS UNDER ACCES-

SORY DRIVE BELT TENSION. IF THIS BRACKET IS

TO BE REMOVED FOR ANY REASON, ALL BELT

TENSION MUST FIRST BE RELIEVED. REFER TO

THE BELT SECTION OF GROUP 7, COOLING SYS-

TEM.

(2) Remove ignition coil from coil mounting bracket

(two bolts).

INSTALLATION3.9L/5.2L ENGINE

(1) I nstall the ignition coil to coil bracket. I f nuts

and bolts are used to secure coil to coil bracket,

tighten to 11 Nm (100 in. lbs.) torque. I f the coil

mounting bracket has been tapped for coil mounting

bolts, tighten bolts to 5 Nm (50 in. lbs.) torque.

(2) Connect all wiring to ignition coil.

HALL EFFECT PICK-UP2.5L ENGINEDistributor removal is not necessary for pick-up re-

moval/installation.

REMOVAL

(1) Remove shield and distributor cap. Refer to

Distributor Removal2.5L Engine.

(2) Remove rotor from shaft (Fi g. 15).

(3) Remove hall effect pick-up assembly (Fig. 16).

INSTALLATION

(1) Place hall effect pick-up assembly into distribu-

tor housing (Fig. 16).

CAUTION: The hall effect pick-up assembly leads

may be damaged if not properly installed (Fig. 16).

(2) I nstall rotor (Fig. 15).

(3) I nstall cap and splash shield. Refer to Distrib-

utor I nstallation2.5L Engine.

INTAKE MANIFOLD AIR TEMPERATURE SENSORFor an operational description, diagnosis or remov-

al/ installation procedures, refer to Group 14, Fuel

Systems.

Fig. 13 Ignition Coil2.5L EngineTypical

Fig. 14 Ignition Coil3.9L/5.2L EngineTypical

Fig. 15 Ignition Rotor2.5L Engine



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MANIFOLD ABSOLUTE PRESSURE(MAP) SENSORFor removal and installation, refer to M anifold Ab-

solute Pressure Sensor in group 14, Fuel Systems.

OXYGEN (O2S) SENSORFor diagnostics and removal/installation proce-

dures, refer to Group 14, F uel Systems, in this man-

ual.

POWERTRAIN CONTROL MODULE (PCM)

REMOVAL

(1) Disconnect negative battery cable at battery.(2) Remove air cleaner duct from the PCM (2.5L

engine only).

(3) Remove 60-way electri cal connector from the

PCM.

(4) Remove (3) P CM mounting screws (Fi g. 17). Re-

move PCM.

INSTALLATION

(1) Check pins in 60-way PCM connector for dam-

age. Repair as necessary.

(2) Connect 60-Way electrical connector to the

PCM (Fig. 17).

(3) Mount PCM to inside right front fender (Fi g.

17). Tighten screws to 4 N m (35 in. lbs.) torque.

(4) I nstall air cleaner duct to the PCM (2.5L only).(5) Connect negative battery cable to battery.

SPARKPLUGS3.9L/5.2L ENGI NE. Spark plug cable heat shields

are pressed into the cylinder head to surround each

cable boot and spark plug (Fig. 18). These shields

protect the spark plug boots from damage (due to in-

tense engine heat generated by the exhaust mani-

folds) and should not be removed. A fter the spark

plug cable has been installed, the lip of the cable boot

should have a small air gap to the top of the heat

shield (Fig. 18).I f r emoval of the heat shield(s) is necessary, remove

the spark plug cable and compress the sides of shield

for removal. Each shield is slotted to allow for com-

pression and removal. To install the shields, align

shield to machined opening in cylinder head and tap

into place with a block of wood.

PLUG REMOVAL

(1) Always r emove spark plug or ignition coil ca-bles by grasping at the cable boot (Fig. 19). Turn the

cable boot 1/2 turn and pull straight back in a steady

motion. Never pull directly on the cable. I nternal

damage to cable will result.

(2) Pr ior to removing the spark plug, spray com-

pressed air around the spark plug hole and the area

around the spark plug. T his will help prevent foreign

materi al from entering the combustion chamber.

(3) Remove the spark plug using a quality socket

with a r ubber or foam insert.

Fig. 16 Hall Effect Pick-Up Assembly2.5L Engine

Fig. 17 Powertrain Control Module (PCM)




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(4) I nspect the spark plug condition. Refer to

Spark Pl ugs in the Diagnostics/Service P rocedures

section of this group.

PLUG CLEANING

The plugs may be cleaned using commercially

avail able spark plug cleaning equipment. After clean-

ing, file the center electrode flat with a small point

fil e or jewelers fil e before adjusting gap.

CAUTION: Never use a motorized wire wheel brush

to clean the spark plugs. Metallic deposits will re-

main on the spark plug insulator and will cause

plug misfire.

PLUG GAP ADJUSTMENT

Check the spark plug gap with a gap gauge tool. I f

the gap is not correct, adjust it by bending the

ground electrode (Fig. 20). Never attempt to adjust

the gap by bending the center electrode.

SPARK PLUG GAP

2.5L Engine Spark Pl ug Gap: .89 mm (.035 in).

3.9L /5.2L Engine Spark Plug Gap: .89 mm (.035

in).

PLUG INSTALLATION

Always tighten spark plugs to the specified torque.Over tightening can cause distortion resulting i n a

change in the spark plug gap or a cracked porcelain

insulator.

When replacing the spark plug and ignition coil ca-

bles, route the cables correctly and secure them inthe appropriate retainers. Failure to route the cablesproperly can cause the radio to reproduce ignitionnoise. I t could cause cross ignition of the spark plugs,or short circuit the cables to ground.

(1) Start the spark plug into the cylinder head byhand to avoid cross threading.

(2) Tighten 2.5L spark plugs to 28 N m (20 ft. lbs.)

torque. Tighten 3.9L/5.2L spark plugs to 35-41 Nm

(26-30 ft. lbs.) torque.

(3) I nstall spark plug cables over spark plugs.

SPARKPLUGSECONDARY CABLES

CAUTION: When disconnecting a high voltage cable

from a spark plug or from the distributor cap, twist

the rubber boot slightly (1/2 turn) to break it loose.Grasp the boot (not the cable) and pull it off with a

steady, even force.

I nstall cables into the proper engine cylinder firi ng

order (Figs. 21, 22 or 23).

When replacing the spark plug and coil cables,

route the cables correctly and secure in the proper

retainers. Failure to route the cables properly can

Fig. 19 Cable Removal

Fig. 20 Setting Spark Plug GapTypical

Fig. 21 Engine Firing Order2.5L Engine



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cause the radio to reproduce ignition noise. I t couldalso cause cross ignition of the plugs, or short circuitthe cables to ground.

When installing new cables, make sure a positiveconnection is made. On the 3.9L/5.2L engine, a snapshould be felt when a good connection is made be-tween the plug cable and the distributor cap tower.

3.9L/5.2L ENGINE: Spark plug cable boot heatshields are pressed into the cylinder head to sur-round each cable boot and spark plug (Fi g. 24). Theseshields protect the spark plug boots from damage

(due to intense engine heat generated by the exhaustmanifolds) and should not be removed. After the

spark plug cable has been i nstalled, the lip of the ca-

ble boot should have a small air gap to the top of the

heat shield (Fig. 24).

CAUTION: 2.5L ENGINE. Do not pull spark plug ca-

bles from distributor cap of a 2.5L engine. The ca-

bles must be released from inside the distributor

cap (Fig. 25).

THROTTLEPOSITION SENSOR (TPS)For removal and installation, r efer to Throttle P o-

sition Sensor in Group 14, Fuel Systems.




Fig. 25 Spark Plug Cable Removal/Installation2.5LEngine



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IGNITION SWITCH

INDEX

page page

General Information . . . . . . . . . . . . . . . . . . . . . . . 27 Ignition Switch and Key Cylinder Service . . . . . . . . 27

GENERAL INFORMATION

The ignition switch is located in the steering col-

umn. The K ey-I n- Switch and Halo L ight are integral

with the ignition switch. Refer to Group 8U for K ey-

In-Switch and Halo Light diagnosis.

IGNITION SWITCH AND KEY CYLINDER SERVICE

REMOVAL

(1) Disconnect negative battery cable.

(2) Tilt column: Remove tilt lever (counterclockwise).

(3) Remove upper and lower shrouds (F ig. 1).

(4) Remove igniti on switch mounting screws (Snap-

on torx bit tool TT XR20B0 or equivalent required

figure 2).

(5) Gently pull switch away from the column. Re-

lease two connector locks on the 7-terminal wiring

connector. Remove the connector from the igniti onswitch.

(6) Release connector lock on the K ey-In-Switchand Halo L ight 4- terminal connector. Remove theconnector from the ignition switch.

TYPE 1 WITH RETAINING PIN

(7) To remove the lock cylinder with retaining pinfrom the ignition switch:

(a) Insert key in the lock cylinder. Turn the key to theLOCK position. U sing a small screwdriver, depress the

lock cylinder retaining pin until it is flush with the lock

cylinder surface (Fig. 3).

(b) Rotate the key clockwise to the OF F position. Thelock cylinder will unseat from the ignition switch (Fig. 4).When the lock cylinder is unseated, it will be approximately1/8 inch away from the ignition switch halo light ring. Donot attempt to remove the lock cylinder at this time.

Fig. 1 Shroud Removal/Installation

Fig. 2 Ignition Switch Screw Removal

Fig. 3 Lock Cylinder with Retaining Pin Type I

IGNITION SYSTEMS 8D - 271995 AN Dakota

Publication No. 81-370-5110

TSB 23-44-94 June 3, 1994


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(c) With the lock cylinder in the unseated position, rotate

the key counterclockwise to the lock position and remove

the key.(d) Remove lock cylinder from ignition switch (Fig. 5).

TYPE II WITH RETAINING SCREW

(7) To remove l ock cylinder with retaining screwfrom ignition switch:

(a) I nsert key in ignition switch. Turn key to L OCKposition. Using a TTXR20A2 or equivalent torx bit, removelock cylinder retaining screw and bracket (Fig. 6).

(b) Rotate key clockwise to the OF F position. L ock

cylinder will unseat from ignition switch (Fig. 4). When

lock cylinder is unseated, it will be approximately 1/8

inch away from ignition switch halo light ring. Do not

attempt to remove lock cylinder at this time.

(c) With lock cylinder in unseated position, rotate key

counterclockwise to the lock position and remove key.(d) Remove lock cylinder from ignition switch (Fig. 7).

INSTALLATION TYPE I

I f the vehicle has floor mounted gear shifter, placethe selector in the Park position.

(1) Connect electrical connectors to the ignitionswitch. Make sure that the switch locking tabs arefully seated in the wiring connectors.

(2) Before attaching the ignition switch to a tilt steering

column, the transaxle shifter must be in the P ark position.Also the park lock dowel pin and the column lock flag must beproperly indexed before installing the switch (Fig. 8).

(a) Place the transaxle shifter in the PARK position.

(b) P lace the ignition switch i n the lock position. Theswitch is in the lock position when the column lock flag isparallel to the ignition switch terminals (Fig. 8).

(c) Position ignition switch park lock dowel pin so it willengage the steering column park l ock slider linkage (Fig. 9).

Fig. 6 Lock Cylinder with Retaining Screw Type II

Fig. 4 Unseated Key Cylinder

Fig. 5 Lock Cylinder Removal

Fig. 7 Key Cylinder Removal

Fig. 8 Ignition Switch View From Column

8D - 28 IGNITION SYSTEMS1995 AN Dakota


TSB 23-44-94 June 3, 1994


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(d) Apply a light coating of grease to the column

lock flag and the park lock dowel pin.

(3) Pl ace the i gnition switch against the lock hous-

ing opening on the steering column. Ensure that the

ignition switch park lock dowel pin enters the slot in

the park lock slider linkage in the steering column.

(4) I nstall ignition switch mounting screws.

Tighten screws to 2 Nm (17 in. lbs.) torque.

(5) I nstall steering column covers. Tighten screws

to 2 Nm (17 in. lbs.) torque.

(6) I f the vehicle is equipped with a tilt steering

column, install the til t lever.

(7) To install the lock in the lock cylinder with re-

taining pin:(a) With the lock cylinder and the ignition switch

in the L ock position, insert the lock cylinder into

the ignition switch until it bottoms.

(b) I nsert ignition key into lock cylinder. While

gently pushing the lock cylinder in toward the ig-

nition switch, rotate the ignition key to the end of

travel.

(c) Connect negative cable to battery.

(8) Check for proper operation of the halo light,

shift lock (if applicable), and column lock. Also check

for proper operation of the igniti on switch accessory,

lock, off, run, and start positions.

INSTALLATION TYPE II

(1) Connect electrical connectors to the ignitionswitch. Make sure that the switch locking tabs arefully seated in the wiring connectors.

(2) Before attaching the ignition switch to a tiltsteering column, the transmission shifter must be in

the Park position. Also the park lock dowel pin andthe column lock flag must be properly indexed beforeinstalling the switch (Fig. 8).

(a) Place the transmission shifter in the PARKposition.

(b) Pl ace the ignition switch i n the lock position.The switch is in the lock position when the columnlock flag is parallel to the ignition switch terminals(Fig. 8).

(c) Position ignition switch park lock dowel pinso i t will engage the steering column park lockslider linkage (Fig. 9).

(d) Apply a light coating of grease to the column

lock flag and the park lock dowel pin.(3) Pl ace the i gnition switch against the lock hous-

ing opening on the steering column. Ensure that theignition switch park lock dowel pin enters the slot inthe park lock slider linkage in the steering column.

(4) I nstall retaining bracket and ignition switchmounting screws. Ti ghten screws to 35 Nm (264in. lbs.) torque.

(5) I nstall ignition lock cylinder:(a) With the lock cylinder and the ignition switch

in the L ock position, insert the lock cylinder intothe ignition switch until it bottoms.

(b) I nsert ignition key into lock cylinder. While

gently pushing the lock cylinder in toward the ig-nition switch, rotate the ignition key to the end oftravel.(6) I nstall retaining screw into bracket and lock

cylinder. Tighten screw to 35 Nm (264 in. lbs.)torque.

(7) I nstall steering column covers. Tighten screwsto 2 Nm (17 in. lbs.) torque.

(8) I f vehicle is equipped with a tilt steering col-umn, install tilt lever.

(9) Connect negative cable to battery.(10) Check for proper operation of the halo light,

shift lock (if applicable), and column lock. Also checkfor proper operation of the ignition switch accessory,lock, off, run, and start positions.

Fig. 9 Ignition Switch Mounting Pad

IGNITION SYSTEMS 8D - 28A1995 AN Dakota


TSB 23-44-94 June 3, 1994


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SPECIFICATIONS

GENERAL INFORMATIONThe following specifications are published from the

latest information available at the time of publica-

tion. If anything differs between the specifica-

tions found on the Vehicle Emission ControlInformation (VECI ) label and the following

specifications, use specifications on VECI label.

The VE CI label is located in the engine compart-

ment.

ENGINE FIRING ORDER2.5L 4-CYLINDER

ENGINE

ENGINE FIRING ORDER3.9L V-6 ENGINE

ENGINE FIRING ORDER5.2L V-8 ENGINE

SPARK PLUG CABLE RESISTANCE

IGNITION COIL RESISTANCE



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