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TJ IGNITION SYSTEM 8D - 1

IGNITION SYSTEM

CONTENTS

page

GENERAL INFORMATIONINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1

DESCRIPTION AND OPERATIONAUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . 3CAMSHAFT POSITION SENSOR . . . . . . . . . . . . . 4CRANKSHAFT POSITION SENSOR . . . . . . . . . . . 3DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2ENGINE COOLANT TEMPERATURE SENSOR . . . 5IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . 3IGNITION SWITCH AND KEY LOCK

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1INTAKE MANIFOLD AIR TEMPERATURE

SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5POWERTRAIN CONTROL MODULE . . . . . . . . . . 2SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . 3SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 2THROTTLE POSITION SENSOR . . . . . . . . . . . . . 5

DIAGNOSIS AND TESTINGAUTOMATIC SHUTDOWN (ASD) RELAY TEST . 5CAMSHAFT POSITION SENSOR . . . . . . . . . . . . . 8CHECK COIL TEST . . . . . . . . . . . . . . . . . . . . . . . 6CRANKSHAFT POSITION SENSOR . . . . . . . . . . . 8DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . . . . 7DISTRIBUTOR ROTOR . . . . . . . . . . . . . . . . . . . . 7ENGINE COOLANT TEMPERATURE SENSOR . . . 9FAILURE TO START TEST . . . . . . . . . . . . . . . . . 6IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . 8INTAKE MANIFOLD AIR TEMPERATURE

SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

page

MAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . 9SPARK PLUG CONDITIONS . . . . . . . . . . . . . . . 10TESTING FOR SPARK AT COIL . . . . . . . . . . . . . 5

REMOVAL AND INSTALLATIONAUTOMATIC SHUTDOWN (ASD) RELAY . . . . . 13CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 15CRANKSHAFT POSITION SENSOR . . . . . . . . . . 14DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 15ENGINE COOLANT TEMPERATURE SENSOR . . 15IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . 13IGNITION SWITCH AND KEY CYLINDER . . . . . 19INTAKE MANIFOLD AIR TEMPERATURE

SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15POWERTRAIN CONTROL MODULE (PCM) . . . 19SHIFTER/IGNITION INTERLOCK . . . . . . . . . . . . 20SPARK PLUG CABLE REMOVAL . . . . . . . . . . . 12SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 12THROTTLE POSITION SENSOR . . . . . . . . . . . . 15

SPECIFICATIONSENGINE FIRING ORDER—2.5L 4-CYLINDER

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21ENGINE FIRING ORDER—4.0L 6-CYLINDER

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21IGNITION COIL RESISTANCE . . . . . . . . . . . . . . 21IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . 20SPARK PLUG CABLE RESISTANCE . . . . . . . . . 21SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 21TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 21VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

GENERAL INFORMATION

INTRODUCTIONThis group describes the ignition systems for both

the 2.5L 4–cylinder and the 4.0L 6–cylinder engines.On Board Diagnostics is described in Group 25,

Emission Control Systems.Group 0, Lubrication and Maintenance, contains

general maintenance information (in time or mileage

intervals) for ignition related items. The Owner’sManual also contains maintenance information.

DESCRIPTION AND OPERATION

IGNITION SYSTEMThe ignition systems used on the 2.5L 4–cylinder

and the 4.0L 6–cylinder engine are basically identi-cal. Similarities and differences between the systemswill be discussed.

8D - 2 IGNITION SYSTEM TJ

DESCRIPTION AND OPERATION (Continued)

The ignition system is controlled by the powertraincontrol module (PCM) on all engines.

The ignition system consists of:• Spark Plugs• Ignition Coil• Secondary Ignition Cables• Distributor (contains rotor and camshaft position

sensor)• Powertrain Control Module (PCM)• Crankshaft Position, Camshaft Position, Throt-

tle Position and MAP Sensors

POWERTRAIN CONTROL MODULEThe Powertrain Control Module (PCM) is located

in the engine compartment (Fig. 1).

The ignition system is controlled by the PCM.

NOTE: Base ignition timing by rotation of distribu-tor is not adjustable.

The PCM opens and closes the ignition coil groundcircuit to operate the ignition coil. This is done toadjust ignition timing, both initial (base) andadvance, and for changing engine operating condi-tions.

The amount of electronic spark advance providedby the PCM is determined by five input factors:engine coolant temperature, engine rpm, intake man-ifold temperature, manifold absolute pressure andthrottle position.

Fig. 1 Powertrain Control Module (PCM) Location

DISTRIBUTORAll 2.5L 4-cylinder and 4.0L-6 cylinder engines are

equipped with a camshaft driven mechanical distrib-utor containing a shaft driven distributor rotor.These distributors are equipped with an internalcamshaft position (fuel sync) sensor (Fig. 2). Thissensor provides fuel injection synchronization andcylinder identification.

The distributors on 2.5L or 4.0L engines do nothave built in centrifugal or vacuum assisted advance.Base ignition timing and all timing advance is con-trolled by the powertrain control module (PCM).Because ignition timing is controlled by the PCM,base ignition timing is not adjustable on any ofthese engines.

The distributor is locked in place by a fork with aslot located on the distributor housing base. The dis-tributor hold-down clamp bolt passes through thisslot when installed. Because the distributor positionis locked when installed, its rotational position cannot be changed. Do not attempt to modify the dis-tributor housing to get distributor rotation.Distributor position will have no effect on igni-tion timing. The position of the distributor willdetermine fuel synchronization only.

All distributors contain an internal oil seal thatprevents oil from entering the distributor housing.The seal is not serviceable.

SPARK PLUGSAll engines use resistor type spark plugs. Remove

the spark plugs and examine them for burned elec-trodes and fouled, cracked or broken porcelain insu-lators. Keep plugs arranged in the order in whichthey were removed from the engine. A single plugdisplaying an abnormal condition indicates that aproblem exists in the corresponding cylinder. Replace

Fig. 2 Distributor and Camshaft Position Sensor(Typical Sensor Shown)



spark plugs at the intervals recommended in GroupO, Lubrication and Maintenance

Spark plugs that have low milage may be cleanedand reused if not otherwise defective, carbon or oilfouled. Refer to the Spark Plug Condition section ofthis group.

SPARK PLUG CABLESSpark plug cables are sometimes referred to as sec-

ondary ignition wires. These cables transfer electricalcurrent from the ignition coil(s) and/or distributor, toindividual spark plugs at each cylinder. The resistivespark plug cables are of nonmetallic construction.The cables provide suppression of radio frequencyemissions from the ignition system.

IGNITION COILBattery 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 coiloperation.

Base ignition timing is not adjustable on anyengine. By controlling the coil ground circuit, thePCM is able to set the base timing and adjust theignition timing advance. This is done to meet chang-ing engine operating conditions.

The ignition coil is not oil filled. The windings areembedded in an epoxy compound. This provides heatand vibration resistance that allows the ignition coilto be mounted on the engine.

AUTOMATIC SHUTDOWN (ASD) RELAYAs one of its functions, the ASD relay will supply

battery voltage to the ignition coil. The ground cir-cuit for the ASD relay is controlled by the PowertrainControl Module (PCM). The PCM regulates ASDrelay operation by switching the ground circuiton-and-off.

CRANKSHAFT POSITION SENSORThe crankshaft position sensor is mounted to the

transmission bellhousing at the left/rear side of theengine block (Fig. 3), (Fig. 4), or (Fig. 5).

Engine speed and crankshaft position are providedthrough the crankshaft position sensor. The sensorgenerates pulses that are the input sent to the pow-ertrain control module (PCM). The PCM interpretsthe sensor input to determine the crankshaft posi-tion. The PCM then uses this position, along withother inputs, to determine injector sequence and igni-tion timing.

The sensor is a hall effect device combined with aninternal magnet. It is also sensitive to steel within acertain distance from it.

SENSOR OPERATIONThe flywheel/drive plate has groups of four notches

at its outer edge. On 4.0L 6-cylinder engines thereare three sets of notches (Fig. 7) or (Fig. 8). On 2.5L4-cylinder engines there are two sets of notches (Fig.6).

The notches cause a pulse to be generated whenthey pass under the sensor. The pulses are the inputto the PCM. For each engine revolution there are twogroups of four pulses generated on 2.5L 4-cylinder

Fig. 3 Crankshaft Position Sensor—4.0L 6-Cyl.Engine—Auto. Trans.




engines. There are 3 groups of four pulses generatedon 4.0L 6-cylinder engines.

The trailing edge of the fourth notch, which causesthe pulse, is four degrees before top dead center(TDC) of the corresponding piston.

The engine will not operate if the PCM does notreceive a crankshaft position sensor input.

Fig. 5 Crankshaft Position Sensor—ManualTransmission (Typical)

Fig. 6 Sensor Operation—2.5L 4-Cyl. Engine

CAMSHAFT POSITION SENSORThe camshaft position sensor is located in the dis-

tributor on all engines (Fig. 2).The sensor contains a hall effect device called a

sync signal generator to generate a fuel sync signal.This sync signal generator detects a rotating pulsering (shutter) on the distributor shaft. The pulse ringrotates 180 degrees through the sync signal genera-

Fig. 7 Sensor Operation—4.0L 6-Cyl. Engine—Manual Transmission

Fig. 8 Sensor Operation—4.0L 6-Cyl. Engine—Automatic Transmission



tor. Its signal is used in conjunction with the crank-shaft position sensor to differentiate between fuelinjection and spark events. It is also used to synchro-nize 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 voltageto switch high resulting in a sync signal of approxi-mately 5 volts.

When the trailing edge of the pulse ring (shutter)leaves the sync signal generator, the following occurs:The change of the magnetic field causes the sync sig-nal voltage to switch low to 0 volts.

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

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

ENGINE COOLANT TEMPERATURE SENSORFor an operational description, diagnosis and


THROTTLE POSITION SENSORFor an operational description, diagnosis and


INTAKE MANIFOLD AIR TEMPERATURE SENSORFor an operational description, diagnosis and


IGNITION SWITCH AND KEY LOCK CYLINDERThe ignition switch is located on the steering col-

umn. The Key-In-Switch is located in the ignitionswitch module. For electrical diagnosis of the Key-In-Switch, refer to Group 8U, Chime/Buzzer WarningSystems. For removal/installation of either the keylock cylinder or ignition switch, refer to IgnitionSwitch and Key Cylinder in this group.

On vehicles equipped with an automatic transmis-sion, a cable connects an interlock device within thesteering column assembly to the transmission floorshift lever. This interlock device is used to lock thetransmission shifter in the PARK position when thekey is in the LOCKED or ACCESSORY position. Theinterlock device is not serviceable. If repair is neces-sary, the steering column assembly must be replaced.Refer to Group 19, Steering for procedures. Theshifter interlock cable can be adjusted or replaced.Refer to Group 21, Transmissions for procedures.

On vehicles equipped with a manual transmission,a lever is located on the steering column behind theignition key lock cylinder. The lever must be operated

to allow rotation of the ignition key lock cylinder. Thelever mechanism is not serviced separately. If repairis necessary, the steering column assembly must bereplaced. Refer to Group 19, Steering for procedures.

DIAGNOSIS AND TESTING

AUTOMATIC SHUTDOWN (ASD) RELAY TESTTo perform a complete test of this relay and its cir-

cuitry, refer to the DRB scan tool. Also refer to theappropriate Powertrain Diagnostics Procedures man-ual. To test the relay only, refer to Relays—Opera-tion/Testing in the Group 14, Fuel Systems section.

TESTING FOR SPARK AT COIL

CAUTION: When disconnecting a high voltagecable from a spark plug or from the distributor cap,twist the rubber boot slightly (1/2 turn) to break itloose (Fig. 9). Grasp the boot (not the cable) andpull it off with a steady, even force.

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

WARNING: BE VERY CAREFUL WHEN THEENGINE IS CRANKING. DO NOT PUT YOUR HANDSNEAR THE PULLEYS, BELTS OR THE FAN. DO NOTWEAR LOOSE FITTING CLOTHING.

(2) Rotate (crank) the engine with the startermotor and observe the cable terminal for a steadyarc. If steady arcing does not occur, inspect the sec-ondary coil cable. Refer to Spark Plug Cables in thisgroup. Also inspect the distributor cap and rotor forcracks or burn marks. Repair as necessary. If steady

Fig. 9 Cable Removal


DIAGNOSIS AND TESTING (Continued)

arcing occurs, connect ignition coil cable to the dis-tributor cap.

(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 rotating the engine with thestarter motor. Observe the spark plug cable terminalfor an arc. If steady arcing occurs, it can be expectedthat the ignition secondary system is operating cor-rectly. (If the ignition coil cable is removed forthis test, instead of a spark plug cable, thespark intensity will be much higher). If steadyarcing occurs at the spark plug cables, but the enginewill not start, connect the DRB scan tool. Refer tothe appropriate Powertrain Diagnostic Proceduresservice manual.

CHECK COIL TESTTo perform a complete test of the ignition coil and

its circuitry, refer to the DRB scan tool. Also refer tothe appropriate Powertrain Diagnostics Proceduresmanual. To test the coil only, refer to the following:

The ignition coil (Fig. 11) or (Fig. 12) is designed tooperate without an external ballast resistor.

Inspect the ignition coil for arcing. Test the coilaccording to coil tester manufacturer’s instructions.Test the coil primary and secondary resistance.Replace any coil that does not meet specifications.Refer to the IGNITION COIL RESISTANCE chart.

If the ignition coil is being replaced, the secondaryspark plug cable must also be checked. Replace cableif it has been burned or damaged.

Fig. 10 Checking for Spark—Typical

Arcing at the tower will carbonize the cable boot,which if it is connected to a new ignition coil, willcause the coil to fail.

If the secondary coil cable shows any signs of dam-age, it should be replaced with a new cable and newterminal. Carbon tracking on the old cable can causearcing and the failure of a new ignition coil.

FAILURE TO START TESTTo prevent unnecessary diagnostic time and wrong

test results, the Testing For Spark At Coil testshould be performed prior to this test.

Fig. 11 Ignition Coil—2.5L Engine


IGNITION COIL RESISTANCE

COIL MANUFACTURERPRIMARY RESISTANCE 21-27°C

(70-80°F)SECONDARY 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



WARNING: SET PARKING BRAKE OR BLOCK THEDRIVE WHEELS BEFORE PROCEEDING WITH THISTEST.

(1) Unplug the ignition coil electrical harness con-nector at the coil (Fig. 11) or (Fig. 12).

(2) Connect a set of small jumper wires (18 gaugeor smaller) between the disconnected harness termi-nals and the ignition coil terminals. To determinepolarity at connector and coil, refer to Group 8W,Wiring Diagrams.

(3) Attach one lead of a voltmeter to the positive(12 volt) jumper wire. Attach the negative side ofvoltmeter to a good ground.

(4) Determine that sufficient battery voltage (12.4volts) is present for the starting and ignition sys-tems.

(5) Crank the engine for 5 seconds while monitor-ing the voltage at the coil positive terminal:

• If the voltage remains near zero during theentire period of cranking, refer to On-Board Diagnos-tics in Group 14, Fuel Systems. Check the Power-train Control Module (PCM) and auto shutdownrelay.

• If voltage is at or near battery voltage and dropsto zero after 1-2 seconds of cranking, check the pow-ertrain control module circuit. Refer to On-BoardDiagnostics in Group 14, Fuel Systems.

• If voltage remains at or near battery voltageduring the entire 5 seconds, turn the key off. Removethe three 32-way connectors (Fig. 13) from the PCM.Check 32-way connectors for any spread terminals orcorrosion.

Fig. 13 PCM and Three 32–Way Connectors

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

(7) Make the special jumper shown in (Fig. 14).Using the jumper, momentarily ground the ignitioncoil driver circuit at the PCM connector (cavity A-7).For cavity/terminal location of this circuit, refer toGroup 8W, Wiring. A spark should be generated atthe coil cable when the ground is removed.

(8) If spark is generated, replace the PCM.(9) If spark is not seen, use the special jumper to

ground the coil negative terminal directly.(10) If spark is produced, repair wiring harness for

an open condition.(11) If spark is not produced, replace the ignition

coil.

DISTRIBUTOR CAPRemove the distributor cap and wipe it clean with

a dry lint free cloth. Visually inspect the cap forcracks, carbon paths, broken towers or damagedrotor button (Fig. 15) or (Fig. 16). Also check forwhite deposits on the inside (caused by condensationentering the cap through cracks). Replace any capthat displays charred or eroded terminals. Themachined surface of a terminal end (faces towardrotor) will indicate some evidence of erosion fromnormal operation. Examine the terminal ends for evi-dence of mechanical interference with the rotor tip.

DISTRIBUTOR ROTORVisually inspect the rotor (Fig. 17) for cracks, evi-

dence of corrosion or the effects of arcing on themetal tip. Also check for evidence of mechanicalinterference with the cap. Some charring is normalon the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radiointerference noise suppression, will appear charred.This is normal. Do not remove the charred com-pound. Test the spring for insufficient tension.Replace a rotor that displays any of these adverseconditions

Fig. 14 Special Jumper Ground-to-Coil NegativeTerminal


.
IGNITION TIMING

NOTE: Base (initial) ignition timing is NOT adjust-able on any 2.5L 4-cylinder or 4.0L 6-cylinderengine. Do not attempt to adjust ignition timing byrotating the distributor.

NOTE: Do not attempt to modify the distributorhousing to get distributor rotation. Distributor posi-tion will have no effect on ignition timing.

All ignition timing functions are controlled by thepowertrain control module (PCM). For additionalinformation, refer to the appropriate PowertrainDiagnostics Procedures service manual for operationof the DRB Scan Tool.

MAP SENSORFor an operational description, diagnosis or remov-

al/ installation procedures, refer to Group 14, FuelSystems.

Fig. 15 Cap Inspection—External—Typical

Fig. 16 Cap Inspection—Internal—Typical

CRANKSHAFT POSITION SENSORTo 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.


tributor (Fig. 18) on all engines.

To perform a complete test of this sensor and itscircuitry, refer to the appropriate Powertrain Diag-nostics Procedures service manual. To test the sensoronly, refer to the following:

For this test, an analog (non-digital) voltme-ter is needed. Do not remove the distributor connec-tor from the distributor. Using small paper clips,

Fig. 17 Rotor Inspection—Typical

Fig. 18 Camshaft Position Sensor—Typical



insert them into the backside of the distributor wireharness connector to make contact with the termi-nals. Be sure that the connector is not damagedwhen inserting the paper clips. Attach voltmeterleads 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. For 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 approximately in the 11 o’clock position.The movable pulse ring should now be within thesensor pickup.

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

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

(7) If voltage is still not present, check for voltageat the supply wire. For wire identification, refer toGroup 8W, Wiring Diagrams.

(8) If 5 volts is not present at supply wire, checkfor voltage at PCM 32-way connector (cavity A-17).Refer to Group 8W, Wiring for location of connector/terminal. Leave the PCM connector connected forthis test.

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

(10) If voltage is present at cavity A-17, but not atthe supply wire:

(a) Check continuity between the supply wire.This is checked between the distributor connectorand cavity A-17 at the PCM. If continuity is notpresent, repair the harness as necessary.

(b) Check for continuity between the camshaftposition sensor output wire and cavity A-18 at thePCM. If continuity is not present, repair the har-ness as necessary.

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

engine with ignition switch. The voltmeter needleshould fluctuate between 0 and 5 volts while theengine is cranking. This verifies that the camshaftposition sensor in the distributor is operating prop-erly and a sync pulse signal is being generated.

If sync pulse signal is not present, replacement ofthe camshaft position sensor is necessary





SPARK PLUG CABLESCheck the spark plug cable connections for good

contact at the coil(s), distributor cap towers, andspark plugs. Terminals should be fully seated. Theinsulators should be in good condition and should fittightly on the coil, distributor and spark plugs. Sparkplug cables with insulators that are cracked or tornmust be replaced.

Clean high voltage ignition cables with a clothmoistened with a non-flammable solvent. Wipe thecables dry. Check for brittle or cracked insulation.

TESTINGWhen testing secondary cables for damage with an

oscilloscope, follow the instructions of the equipmentmanufacturer.

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

CAUTION: Do not leave any one spark plug cabledisconnected for longer than necessary during test-ing. This may cause possible heat damage to thecatalytic converter. Total test time must not exceedten minutes.

With the engine running, remove spark plug cablefrom spark plug (one at a time) and hold next to agood engine ground. If the cable and spark plug arein good condition, the engine rpm should drop andthe engine will run poorly. If engine rpm does notdrop, the cable and/or spark plug may not be operat-ing properly and should be replaced. Also checkengine cylinder 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. If cables are crackedor punctured, there will be a noticeable spark jumpfrom the damaged area to the test probe. The cablerunning 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 wordsELECTRONIC SUPPRESSION 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 ofcable and to corresponding electrode in distributorcap. Resistance should be 250 to 1000 Ohms per inchof cable. If not, remove cable from distributor captower and connect ohmmeter to the terminal ends ofcable. If resistance is not within specifications asfound in the SPARK PLUG CABLE RESISTANCEchart, replace the cable. Test all spark plug cables inthis manner.

To test ignition coil-to-distributor cap cable, do notremove the cable from the cap. Connect ohmmeter torotor button (center contact) of distributor cap andterminal at ignition coil end of cable. If resistance isnot within specifications as found in the Spark PlugCable Resistance chart, remove the cable from thedistributor cap. Connect the ohmmeter to the termi-nal ends of the cable. If resistance is not within spec-ifications as found in the Spark Plug CableResistance chart, replace the cable. Inspect the igni-tion coil tower for cracks, burns or corrosion.

SPARK PLUG CONDITIONS

NORMAL OPERATINGThe few deposits present on the spark plug will

probably be light tan or slightly gray in color. This isevident with most grades of commercial gasoline(Fig. 19). There will not be evidence of electrodeburning. Gap growth will not average more thanapproximately 0.025 mm (.001 in) per 1600 km (1000miles) of operation. Spark plugs that have normalwear can usually be cleaned, have the electrodesfiled, have the gap set and then be installed.

Some fuel refiners in several areas of the UnitedStates have introduced a manganese additive (MMT)for unleaded fuel. During combustion, fuel with MMTcauses the entire tip of the spark plug to be coatedwith a rust colored deposit. This rust color can bemisdiagnosed as being caused by coolant in the com-bustion chamber. Spark plug performance is notaffected by MMT deposits.

COLD FOULING/CARBON FOULINGCold fouling is sometimes referred to as carbon

fouling. The deposits that cause cold fouling are basi-cally carbon (Fig. 19). A dry, black deposit on one ortwo plugs in a set may be caused by sticking valvesor defective spark plug cables. Cold (carbon) fouling

SPARK PLUG CABLE RESISTANCE

MINIMUM MAXIMUM

250 Ohms Per Inch 1000 Ohms Per Inch

3000 Ohms Per Foot 12,000 Ohms Per Foot

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 FOULINGA spark plug coated with excessive wet fuel or oil

is wet fouled. In older engines, worn piston rings,leaking valve guide seals or excessive cylinder wearcan cause wet fouling. In new or recently overhauledengines, wet fouling may occur before break-in (nor-mal oil control) is achieved. This condition can usu-ally be resolved by cleaning and reinstalling thefouled plugs.

OIL OR ASH ENCRUSTEDIf one or more spark plugs are oil or oil ash

encrusted (Fig. 20), evaluate engine condition for thecause of oil entry into that particular combustionchamber.

ELECTRODE GAP BRIDGINGElectrode gap bridging may be traced to loose

deposits in the combustion chamber. These depositsaccumulate on the spark plugs during continuousstop-and-go driving. When the engine is suddenlysubjected to a high torque load, deposits partially liq-uefy and bridge the gap between electrodes (Fig. 21).This short circuits the electrodes. Spark plugs withelectrode gap bridging can be cleaned using standardprocedures.

SCAVENGER DEPOSITSFuel scavenger deposits may be either white or yel-

low (Fig. 22). They may appear to be harmful, butthis is a normal condition caused by chemical addi-tives in certain fuels. These additives are designed tochange the chemical nature of deposits and decreasespark plug misfire tendencies. Notice that accumula-tion on the ground electrode and shell area may be

Fig. 19 Normal Operation and Cold (Carbon) Fouling



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 INSULATORA chipped electrode insulator usually results from

bending the center electrode while adjusting thespark plug electrode gap. Under certain conditions,severe detonation can also separate the insulatorfrom the center electrode (Fig. 23). Spark plugs withthis condition must be replaced.

PREIGNITION DAMAGEPreignition damage is usually caused by excessive

combustion chamber temperature. The center elec-

Fig. 20 Oil or Ash Encrusted

Fig. 21 Electrode Gap Bridging

trode dissolves first and the ground electrode dis-solves somewhat latter (Fig. 24). Insulators appearrelatively deposit free. Determine if the spark plughas the correct heat range rating for the engine.Determine 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 porcelaininsulator.)

SPARK PLUG OVERHEATINGOverheating is indicated by a white or gray center

electrode insulator that also appears blistered (Fig.25). The increase in 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 rating should be used. Over advanced ignitiontiming, detonation and cooling system malfunctionscan also cause spark plug overheating

Fig. 22 Scavenger Deposits

Fig. 23 Chipped Electrode Insulator


.
REMOVAL AND INSTALLATION

SPARK PLUG CABLE REMOVAL

CAUTION: When disconnecting a high voltagecable from a spark plug or from the distributor cap,twist the rubber boot slightly (1/2 turn) to break itloose (Fig. 26). Grasp the boot (not the cable) andpull it off with a steady, even force.

SPARK PLUGS

PLUG REMOVAL(1) Always remove spark plug or ignition coil

cables by grasping at the cable boot (Fig. 26). Turnthe cable boot 1/2 turn and pull straight back in asteady motion. Never pull directly on the cable.Internal damage to cable will result.

(2) Prior to removing the spark plug, spray com-pressed air around the spark plug hole and the area

Fig. 24 Preignition Damage

Fig. 25 Spark Plug Overheating

around the spark plug. This will help prevent foreignmaterial from entering the combustion chamber.

(3) Remove the spark plug using a quality socketwith a rubber or foam insert.

(4) Inspect the spark plug condition. Refer toSpark Plugs in the Diagnostics/Service Proceduressection of this group.

PLUG CLEANINGThe plugs may be cleaned using commercially

available spark plug cleaning equipment. After clean-ing, file the center electrode flat with a small pointfile or jewelers file before adjusting gap.

CAUTION: Never use a motorized wire wheel brushto clean the spark plugs. Metallic deposits willremain on the spark plug insulator and will causeplug misfire.

PLUG GAP ADJUSTMENTCheck the spark plug gap with a gap gauge tool. If

the gap is not correct, adjust it by bending theground electrode (Fig. 27). Never attempt to adjustthe gap by bending the center electrode.

SPARK PLUG GAP• 2.5L 4-Cylinder Engine Spark Plug Gap: .89 mm

(.035 in).• 4.0L 6-Cylinder Engine Spark Plug Gap: .89 mm

(.035 in).

PLUG INSTALLATIONAlways tighten spark plugs to the specified torque.

Over tightening can cause distortion. This may resultin a change in the spark plug gap, or a cracked por-celain insulator.

When replacing the spark plug and ignition coilcables, route the cables correctly and secure them inthe appropriate retainers. Failure to route the cables

Fig. 26 Cable Removal


REMOVAL AND INSTALLATION (Continued)

properly can cause the radio to reproduce ignitionnoise. 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 byhand to avoid cross threading.

(2) Tighten the spark plugs to 35-41 N·m (26-30 ft.lbs.) torque.

(3) Install spark plug cables over spark plugs.

IGNITION COILThe ignition coil is an epoxy filled type. If the coil

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

REMOVALOn the 2.5L 4-cylinder engine, the ignition coil is

mounted to a bracket on the side of the engine (tothe rear of the distributor) (Fig. 28).

On the 4.0L 6-cylinder engine, the ignition coil ismounted to a bracket on the side of the engine (tothe front of the distributor) (Fig. 29).

(1) Disconnect the ignition coil secondary cablefrom ignition coil.

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

(3) Remove ignition coil mounting bolts (nuts areused on back side of bracket on some coils).

(4) Remove coil from vehicle.

INSTALLATION(1) Install ignition coil to bracket on cylinder block

with mounting bolts (and nuts if equipped). Ifequipped with nuts and bolts, tighten to 11 N·m (100

Fig. 27 Setting Spark Plug Gap—Typical

in. lbs.) torque. If equipped with bolts only, tighten to5 N·m (50 in. lbs.) torque.

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

AUTOMATIC SHUTDOWN (ASD) RELAYThe ASD relay is located in the Power Distribution

Center (PDC) (Fig. 30). Relay location is printed on alabel on PDC cover.

REMOVAL(1) Remove the PDC cover.(2) Remove the relay by lifting straight up.

INSTALLATION(1) Check condition of relay terminals at PDC for

corrosion or damage. Also check the heights of relayterminal pins at PDC. Pin height should be same forall pins. Repair as necessary before installing relay.

(2) Push the relay into the connector.(3) Install the relay cover.





CRANKSHAFT POSITION SENSORThe crankshaft position sensor is mounted to the

transmission bellhousing at the left/rear side of theengine block (Fig. 31), (Fig. 32), or (Fig. 33).

On 2.5L 4-cylinder and 4.0L 6-cylinder engineswith manual transmissions, the sensor is attachedwith two bolts. On 2.5L engines with automatictransmissions, the sensor is attached with two nuts.On 4.0L engines with automatic transmissions, thesensor is adjustable and is attached with one bolt.

REMOVAL(1) Near rear of intake manifold, disconnect pigtail

harness (electrical connector) from main electricalharness.

(2) Depending upon application, remove either sen-sor mounting bolt(s) or nuts.

(3) Remove sensor from engine.

Fig. 30 PDC Location


INSTALLATION2.5L and 4.0L engines with manual transmis-

sion:(1) Install sensor flush against opening in trans-

mission housing.(2) Install and tighten two sensor mounting bolts

to 19 N·m (14 ft. lbs.) torque. The two sensor mount-ing bolts are specially machined to correctly space


Fig. 33 Crankshaft Position Sensor—ManualTransmission (Typical)



unit to flywheel. Do not attempt to install any otherbolts.

2.5L engines with automatic transmission:(3) Install and tighten two sensor mounting nuts

to 19 N·m (14 ft. lbs.) torque.4.0L engines with automatic transmission:New replacement sensors will be equipped with a

paper spacer glued to bottom of sensor. If installing(returning) a used sensor to vehicle, a new paperspacer must be installed to bottom of sensor. Thisspacer will be ground off the first time engine isstarted. If spacer is not used, sensor will be brokenthe first time engine is started.

(4) New Sensors: Be sure paper spacer is installedto bottom of sensor. If not, obtain spacerPN05252229.

(5) Used Sensors: Clean bottom of sensor andinstall spacer PN05252229.

(6) Install sensor into transmission bellhousinghole.

(7) Push sensor against flywheel/drive plate. Withsensor pushed against flywheel/drive plate, tightenmounting bolt to 7 N·m (60 in. lbs.) torque.

(8) Connect sensor pigtail harness electrical con-nector to main wiring harness.


tributor (Fig. 34).

REMOVALDistributor removal is not necessary to remove

camshaft 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.

Fig. 34 Camshaft Position Sensor

(4) Remove distributor rotor from distributor shaft.(5) Lift the camshaft position sensor assembly

from the distributor housing (Fig. 34).

INSTALLATION(1) Install camshaft position sensor to distributor.

Align sensor into notch on distributor housing.(2) Connect wiring harness.(3) Install rotor.(4) Install distributor cap. Tighten mounting

screws.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORFor removal and installation, refer to Manifold

Absolute Pressure Sensor in group 14, Fuel Systems.



THROTTLE POSITION SENSORFor an operational description, diagnosis and




DISTRIBUTORAll distributors contain an internal oil seal that

prevents oil from entering the distributor housing.The seal is not serviceable.

Factory replacement distributors are equipped witha plastic alignment pin already installed. The pin islocated in an access hole on the bottom of the distrib-utor housing (Fig. 35). It is used to temporarily lockthe rotor to the cylinder number 1 position duringinstallation. The pin must be removed after install-ing the distributor.

The camshaft position sensor is located in the dis-tributor on all engines (Fig. 36). For removal/instal-lation procedures, refer to Camshaft Position Sensor.Distributor removal is not necessary for sensorremoval.

Refer to (Fig. 36) for an exploded view of the dis-tributor.

A fork with a slot is supplied on the bottom of thedistributor housing where the housing base seatsagainst the engine block (Fig. 36). The centerline ofthe slot aligns with the distributor hold-down bolthole in the engine block. Because of the fork, the dis-tributor cannot be rotated. Distributor rotation is notnecessary as all ignition timing requirements arehandled by the powertrain control module (PCM).



The position of the distributor determines fuel syn-chronization only. It does not determine ignition tim-ing.

Fig. 35 Plastic Alignment Pin

Fig. 36 Distributor—2.5L Or 4.0L Engines—Typical

NOTE: Do not attempt to modify this fork to attainignition timing.

REMOVAL—2.5L OR 4.0L ENGINE(1) Disconnect the negative battery cable at the

battery.(2) Disconnect coil secondary cable at coil.(3) Remove distributor cap from distributor (2

screws). Do not remove cables from cap. Do notremove rotor.

(4) Disconnect the distributor wiring harness fromthe main engine harness.

(5) Remove the cylinder number 1 spark plug.(6) Hold a finger over the open spark plug hole.

Rotate the engine at the vibration dampener boltuntil compression (pressure) is felt.

(7) Slowly continue to rotate the engine. Do thisuntil the timing index mark on the vibration damperpulley aligns with the top dead center (TDC) mark (0degree) on timing degree scale (Fig. 37). Alwaysrotate the engine in direction of normal rotation. Donot rotate the engine backward to align the timingmarks.

(8) Remove the distributor hold-down bolt andclamp.

(9) Remove the distributor from engine by slowlylifting straight up.

(10) Note that the rotor will rotate slightly in acounterclockwise direction while lifting up the dis-tributor. The oil pump gear will also rotate slightly ina counterclockwise direction while lifting up the dis-

Fig. 37 Align Timing Marks



tributor. This is due to the helical cut gears on thedistributor and camshaft.

(11) Note the removed position of the rotor duringdistributor removal. During installation, this will bereferred to as the Pre-position.

(12) 2.5L 4-Cylinder Engine: Observe the slot inthe oil pump gear through the hole on the side of theengine. It should be slightly before (counterclockwiseof) the 10 o’clock position (Fig. 38).

(13) 4.0L 6-Cylinder Engine: Observe the slot inthe oil pump gear through the hole on the side of theengine. It should be slightly before (counterclockwiseof) the 11 o’clock position (Fig. 39).

(14) Remove and discard the old distributor-to-en-gine block gasket.

INSTALLATION(1) If the engine crankshaft has been rotated after

distributor removal, cylinder number 1 must bereturned to its proper firing stroke. Refer to previousREMOVAL Step 5 and Step 6. These steps must bedone before installing distributor.

Fig. 38 Slot At 10 O’clock Position—2.5L Engine

Fig. 39 Slot At 11 O’clock Position—4.0L Engine

(2) Check the position of the slot on the oil pumpgear. On the 2.5L engine, it should be just slightlybefore (counterclockwise of) the 10 o’clock position(Fig. 38). On the 4.0L engine, it should be justslightly before (counterclockwise of) the 11 o’clockposition (Fig. 39). If not, place a flat blade screw-driver into the oil pump gear and rotate it into theproper position.

(3) Factory replacement distributors are equippedwith a plastic alignment pin already installed (Fig.35). This pin is used to temporarily hold the rotor tothe cylinder number 1 firing position during distrib-utor installation. If this pin is in place, proceed toStep 8. If not, proceed to next step.

(4) If the original distributor is to be reinstalled,such as during engine overhaul, the plastic pin willnot be available. A 3/16 inch drift pin punch tool maybe substituted for the plastic pin.

(5) Remove the camshaft position sensor from thedistributor housing. Lift straight up.

(6) Four different alignment holes are provided onthe plastic ring (Fig. 40). Note that 2.5L and 4.0Lengines have different alignment holes (Fig.40).

(7) Rotate the distributor shaft and install the pinpunch tool through the proper alignment hole in theplastic ring (Fig. 40) and into the mating access holein the distributor housing. This will prevent the dis-tributor shaft and rotor from rotating.

(8) Clean the distributor mounting hole area of theengine block.

(9) Install a new distributor-to-engine block gasket(Fig. 36).

Fig. 40 Pin Alignment Holes



(10) Install the rotor to the distributor shaft.(11) 2.5L 4-Cylinder Engine: Pre-position the

distributor into the engine while holding the center-line of the base slot in the 1 o’clock position (Fig. 41).Continue to engage the distributor into the engine.The rotor and distributor will rotate clockwise duringinstallation. This is due to the helical cut gears onthe distributor and camshaft. When the distributor isfully seated to the engine block, the centerline of thebase slot should be aligned to the clamp bolt mount-ing hole on the engine (Fig. 42). The rotor shouldalso be pointed slightly past (clockwise of) the 3o’clock position.

4.0L 6-Cylinder Engine: Pre-position the distrib-utor into the engine while holding the centerline ofthe base slot in the 1 o’clock position (Fig. 41). Con-tinue to engage the distributor into the engine. Therotor and distributor will rotate clockwise duringinstallation. This is due to the helical cut gears onthe distributor and camshaft. When the distributor isfully seated to the engine block, the centerline of thebase slot should be aligned to the clamp bolt mount-ing hole on the engine (Fig. 43). The rotor shouldalso be pointed at the 5 o’clock position.

It may be necessary to rotate the rotor and distrib-utor shaft (very slightly) to engage the distributorshaft with the slot in the oil pump gear. The samemay have to be done to engage the distributor gearwith the camshaft gear.

The distributor is correctly installed when:• the rotor is pointed at the 3 o’clock position

(2.5L engine), or at the 5 o’clock position (4.0Lengine).

Fig. 41 Distributor Pre-position—All Engines

• the plastic alignment pin (or pin punch tool) isstill installed to distributor.

• the number 1 cylinder piston is set at top deadcenter (TDC) (compression stroke).

• the centerline of the slot at the base of the dis-tributor is aligned to the centerline of the distributorhold-down bolt hole on the engine. In this position,

Fig. 42 Distributor Engaged Position—2.5L4-Cylinder Engine

Fig. 43 Distributor Engaged Position—4.0L6-Cylinder Engine



the hold-down bolt should easily pass through theslot and into the engine.

No adjustments are necessary. Proceed to nextstep.

(12) Install the distributor hold-down clamp andbolt. Tighten the bolt to 23 N·m (17 ft. lbs.) torque.

(13) Remove the pin punch tool from the distribu-tor. Or, if the plastic alignment pin was used, removeit straight down from the bottom of the distributor.Discard plastic pin.

(14) If removed, install the camshaft position sen-sor to the distributor. Align the wiring harness grom-met to the notch in the distributor housing.

(15) Install the rotor.

CAUTION: If the distributor cap is incorrectly posi-tioned on distributor housing, the cap or rotor maybe damaged when engine is started.

(16) Install the distributor cap. Tighten distributorcap hold-down screws to 3 N·m (26 in. lbs.) torque.

(17) If removed, install the spark plug cables tothe distributor cap. For proper firing order, refer tothe Specifications section at the end of this group.See Engine Firing Order.

(18) Connect the distributor wiring harness to themain engine harness.

(19) Connect battery cable to battery.

POWERTRAIN CONTROL MODULE (PCM)Refer to Group 14, Fuel System for procedures.

IGNITION SWITCH AND KEY CYLINDERThe ignition key must be in the key cylinder for

cylinder removal. The key cylinder must be removedfirst before removing ignition switch.

KEY CYLINDER REMOVAL(1) Disconnect negative battery cable at battery.(2) If equipped with an automatic transmission,

place shifter in PARK position.(3) Rotate key to ON position.(4) A release tang is located on bottom of key cyl-

inder (Fig. 44).(5) Position a small screwdriver or pin punch into

tang access hole on bottom of steering column lowercover (Fig. 45).

(6) Push the pin punch up while pulling key cylin-der from steering column.

IGNITION SWITCH REMOVAL(1) Remove key cylinder. Refer to previous steps.(2) Remove lower steering column cover screws

and remove cover (Fig. 45).(3) Disconnect two electrical connectors at rear of

ignition switch (Fig. 46).

(4) Remove ignition switch mounting screw (Fig.46). Use tamper proof torx bit (Snap-Ont SDMTR10or equivalent) to remove the screw.

(5) Using a small screwdriver, push on locking tab(Fig. 47) and remove switch from steering column.

IGNITION SWITCH INSTALLATION(1) Before installing ignition switch, rotate the slot

in the switch to the ON position (Fig. 48).(2) Position switch to column and install tamper

proof screw. Tighten screw to 3 N·m (26 in. lbs.).(3) Connect two electrical connectors to rear of

ignition switch. Make sure that locking tabs are fullyseated into wiring connectors.

(4) Install steering column lower cover.

Fig. 44 Key Cylinder Release Tang

Fig. 45 Key Cylinder and Cover Removal



KEY CYLINDER INSTALLATION(1) If equipped with an automatic transmission,

place shifter in PARK position.(2) Position key cylinder into steering column as it

would normally be in the ON position.(3) Press key cylinder into column until it snaps

into position.(4) Check mechanical operation of switch. Auto-

matic Transmission: Be sure transmission lever islocked in PARK position after key removal. If key is

Fig. 46 Ignition Switch Removal/Installation

Fig. 47 Ignition Switch Lock Tab

difficult to rotate or is difficult to remove, the shiftlever-to-steering column cable may be out of adjust-ment or defective. Refer to Group 21, Transmissionfor procedures. Manual Transmission: Be sure keycannot be removed until release lever is operated. Ifkey can be removed, release lever mechanism may bedefective. Release lever mechanism is not servicedseparately. If repair is necessary, the steering columnmust be replaced. Refer to Group 19, Steering forprocedures.

(5) Connect negative cable to battery.(6) Check electrical operation of switch.

SHIFTER/IGNITION INTERLOCKOn models equipped with an automatic transmis-

sion, a cable connects the ignition switch with thefloor shift lever. The shifter will be locked in thePARK position when the ignition key is in the LOCKor ACCESSORY positions. The cable can be adjustedor replaced. Refer to Group 21, Transmissions forprocedures. The ignition interlock device within thesteering column is not serviceable. If service is nec-essary, the steering column must be replaced. Referto Group 19, Steering for procedures.

SPECIFICATIONS

VECI LABELIf anything differs between the specifications found

on the Vehicle Emission Control Information (VECI)label and the following specifications, use specifica-tions on VECI label. The VECI label is located in theengine compartment.

IGNITION TIMINGIgnition timing is not adjustable on any engine. Refer

to Ignition Timing in the Diagnostics/Service Proceduressection of this group for more information.

Fig. 48 Switch In ON Position


SPECIFICATIONS (Continued)

ENGINE FIRING ORDER—2.5L 4-CYLINDERENGINE

ENGINE FIRING ORDER—4.0L 6-CYLINDERENGINE

TORQUE CHART

DESCRIPTION TORQUECrankshaft Position Sensor

Bolts—With ManualTransmission . . . . . . . . . . . .19 N·m (14 ft. lbs.)

Crankshaft Position SensorNuts—2.5L With AutomaticTransmission . . . . . . . . . . . . . .19 N·m (14 ft. lbs.)

Crankshaft Position SensorBolt—4.0L With AutomaticTransmission . . . . . . . . . . . . . .7 N·m (60 in. lbs.)

Distributor Hold Down Bolt . . . . .23 N·m (17 ft. lbs.)Distributor Cap Screws . . . . . . . . .3 N·m (26 in. lbs.)Ignition Coil Mounting (if tapped

bolts are used) . . . . . . . . . . . . . .5 N·m (50 in. lbs.)Ignition Coil Mounting (if nuts/bolts

are used) . . . . . . . . . . . . . . . .11 N·m (100 in. lbs.)Spark Plugs (all engines) . . . . . . .41 N·m (30 ft. lbs.)

SPARK PLUGS

SPARK PLUG CABLE RESISTANCE

ENGINE PLUG TYPEELECTRODE

GAP

2.5L/4.0L RC12LYC 0.89 mm (0.035in.)

MINIMUM MAXIMUM

250 Ohms Per Inch 1000 Ohms Per Inch

3000 Ohms Per Foot 12,000 Ohms Per Foot

IGNITION COIL RESISTANCE

COIL MANUFACTURERPRIMARY RESISTANCE 21-27°C

(70-80°F)SECONDARY 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

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