ignition system - service information - story time with keith

2007 ENGINE

Ignition System - Service Information - 300, Charger & Magnum

IGNITION SYSTEM - SERVICE INFORMATION

DESCRIPTION

IGNITION SYSTEM

The ignition system used on these engines is referred to as the Direct Ignition System (DIS). The system's three main components are the coils, crankshaft position sensor, and camshaft position sensor. If equipped with the coil on plug ignition system it utilizes an ignition coil for every cylinder, it is mounted directly over each spark plug.

OPERATION

IGNITION SYSTEM

The crankshaft position sensor and camshaft position sensor are hall effect devices. The camshaft position sensor and crankshaft position sensor generate pulses that are inputs to the PCM. The PCM determines engine position from these sensors. The PCM calculates injector sequence and ignition timing from crankshaft & camshaft position.

SPECIFICATIONS

TORQUE

TORQUE SPECIFICATIONS

NOTE: All engines use a fixed ignition timing system. Basic ignition timing is not adjustable. All spark advance is determined by the Powertrain Control Module (PCM).

DESCRIPTION N.m Ft. Lbs. In. Lbs.Camshaft Position Sensor - 2.7L 12 - 105Camshaft Position Sensor - 3.5L 12 - 105Camshaft Position Sensor - 5.7L V8 Engine

12 9 105

Crankshaft Position Sensor - 2.7L 12 - 105Crankshaft Position Sensor - 3.5L 12 - 105Crankshaft Position Sensor - 5.7L V8 Engine

12 9 105

Ignition Coil Mounting - 2.7L 6 - 55Ignition Coil Mounting - 3.5L 7 - 60Ignition Coil Mounting - 5.7L V8 Engine 12 9 105 (± 20)

2007 Chrysler 300 SRT-8

2007 ENGINE Ignition System - Service Information - 300, Charger & Magnum



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Thursday, April 01, 2010 1:12:58 PM © 2006 Mitchell Repair Information Company, LLC.

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Thursday, April 01, 2010 1:13:03 PM Page 1 © 2006 Mitchell Repair Information Company, LLC.

SPECIFICATIONS - SPARK PLUGS

SPARK PLUG SPECIFICATIONS

SENSOR - CAMSHAFT POSITION

REMOVAL

CAMSHAFT POSITION SENSOR - 2.7L

Ignition Coil Mounting - 6.1L V8 Engine 6 - 8 - 53 - 71Knock Sensor - 2.7L 10 7 -Knock Sensor - 3.5L 20 15 -* Knock Sensor - 5.7/6.1L V8 Engine 20 15 176Spark Plugs - 2.7L 17 - 150Spark Plugs - 3.5L 28 20 -** Spark Plugs - 5.7L V8 Engine 18 (± 3) 13 (± 2) -** Spark Plugs - 6.1L V8 Engine 15 - 20 11 - 15 -Capacitor Nut 12 9 106* Do not apply any sealant, thread-locker or adhesive to bolts. Poor sensor performance may result.** Torque critical tapered design. Do not exceed 15 ft. lbs.

ENGINE PLUG TYPE ELECTRODE GAP2.7L RE10PMC5 0.048-0.058 in.3.5L ZFR5LP-13G 0.048-0.058 in.5.7L Hemi V8 Champion - RE14MCC4 1.14 mm (0.045 in.)6.1L Hemi V8 NGK PLZTR5A-13 1.3 mm (0.050 in.)



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Fig. 1: Cam Sensor - 2.7L Courtesy of CHRYSLER LLC

1. Disconnect negative battery cable.

2. Unlock and disconnect electrical connector.



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Fig. 2: Removing Cam Sensor - 2.7L Courtesy of CHRYSLER LLC

3. Remove mounting bolt.

4. Remove sensor.




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1. Camshaft Position Sensor location.




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Fig. 4: Removing Connector Courtesy of CHRYSLER LLC

3. Unlock electrical connector.

4. Remove electrical connector.



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Fig. 5: Cam Sensor Spacer - 3.5L Courtesy of CHRYSLER LLC

5. Remove mounting bolt.

6. Remove sensor.




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Fig. 6: Camshaft Position Sensor - 5.7L Courtesy of CHRYSLER LLC

The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine (1) is bolted to the front/top of the timing chain cover (2).

1. Disconnect electrical connector (4) at CMP sensor.

2. Remove sensor mounting bolt (3).

3. Carefully twist sensor from timing chain cover.

4. Check condition of sensor O-ring.




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The Camshaft Position Sensor (CMP) on the 6.1L V-8 engine (1) is bolted to the front/top of the timing chain cover (2).

1. Disconnect electrical connector (4) at CMP sensor.

2. Remove sensor mounting bolt (3).

3. Carefully twist sensor from timing chain cover.

4. Check condition of sensor O-ring.

INSTALLATION




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Fig. 8: Removing Cam Sensor - 2.7L Courtesy of CHRYSLER LLC

1. Install sensor.

2. Install mounting bolt.

3. Tighten bolt to 12 N.m (105 in. lbs.).



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4. Connect electrical connector and lock.

5. Connect negative battery cable.




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Fig. 10: Cam Sensor Spacer - 3.5L Courtesy of CHRYSLER LLC

1. Install new spacer to sensor if installing the old sensor or new sensor will have the spacer installed.



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2. Install sensor and insert until sensor makes contact with tone wheel.


4. Tighten mounting bolt to 12 N.m (105 in. lbs.).



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Fig. 12: Connector Locked Courtesy of CHRYSLER LLC

5. Install electrical connector.

6. Lock connector.





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1. Clean out machined hole in timing chain cover.

2. Apply a small amount of engine oil to sensor O-ring.

3. Install sensor (1) into timing chain cover (2) with a slight rocking action. Do not twist sensor into position as damage to O-ring may result.

4. Install mounting bolt (3) and tighten to 12 N.m (105 in. lbs.)

5. Connect electrical connector (4) to sensor.


CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result.



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1. Clean out machined hole in timing chain cover.

2. Apply a small amount of engine oil to sensor O-ring.

3. Install sensor (1) into timing chain cover (2) with a slight rocking action. Do not twist sensor into position as damage to O-ring may result.

4. Install mounting bolt (3) and tighten to 12 N.m (105 in. lbs.)

5. Connect electrical connector (4) to sensor.

COIL - IGNITION

REMOVAL

CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result.



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IGNITION COIL - 2.7L

Fig. 15: Ignition Coils Courtesy of CHRYSLER LLC


2. Remove the intake manifold. Refer to REMOVAL .

3. Prior to removing the ignition coils, spray compressed air around the coil area and spark plug.



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Fig. 16: Removing/Installing Ignition Coil Courtesy of CHRYSLER LLC

4. Remove electrical connector from ignition coil.

5. Remove 2 fasteners from ignition coil assembly.

6. Remove ignition coil assembly.




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3. Prior to removing the ignition coils, spray compressed air around the coil area.

4. Unlock and remove electrical connector from ignition coil.



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On 3.5L engines, it is necessary to loosen the screws by alternating back and forth. Do not lose the spacers under the coil when loosening the screws.

5. Remove 2 fasteners from ignition coil assembly.

6. Remove ignition coil assembly.

IGNITION COIL - 5.7/6.1L



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Fig. 19: Ignition Coil Location - 6.1L Courtesy of CHRYSLER LLC

A separate ignition coil (1), mounted to the valve cover is used for each cylinder. Each coil fires the two spark plugs at times predetermined by the Powertrain Control Module (PCM).



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Fig. 20: Ignition Coil Mounting Bolts - 5.7L/6.1L Courtesy of CHRYSLER LLC

1. Unlock electrical connector (1) by pressing on tab while pulling electrical connector from coil.

2. Remove two coil mounting bolts (3).



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3. Carefully pull up coil from cylinder head opening with a slight twisting action. Twisting will help break loose boots (1) from spark plugs.

INSTALLATION




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1. Install ignition coil assembly to spark plug.

2. Install coil screws and tighten: 2.7L engine to 6 N.m (55 in. lbs.).

3. Connect the electrical connector and lock.



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4. Install the intake manifold. Refer to INSTALLATION .





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On 3.5L engines, it is necessary to tighten the screws by alternating back and forth. Do not lose the spacers under the coil when installing ignition coils.

1. Install ignition coil assembly to spark plug.

2. Install coil screws and tighten 3.5L engines to 7 N.m (60 in. lbs.).

3. Connect the electrical connector and lock.



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IGNITION COIL - 5.7/6.1L



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1. Before installing coil(s), apply dielectric grease to inside of spark plug boots (1).



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Fig. 27: Ignition Coil Mounting Bolts - 5.7L/6.1L Courtesy of CHRYSLER LLC

2. Position ignition coil into valve cover and push both spark plug boots onto each spark plug.

3. Install two coil mounting bolts (3) and tighten to 12 N.m (105 in. lbs.).

4. Connect electrical connector (1) to coil and lock connector.

CAPACITOR - IGNITION COIL

REMOVAL

IGNITION COIL CAPACITOR



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Fig. 28: Ignition Coil Capacitor - Right Side Courtesy of CHRYSLER LLC

1. Remove the negative battery cable.

2. Disconnect the electrical connector.

3. Remove nut and capacitor.

IGNITION COIL CAPACITOR - 6.1L



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Fig. 29: Capacitor - 6.1L Courtesy of CHRYSLER LLC

The ignition capacitor (2) is attached to the left-rear corner of the intake manifold (3).

1. Remove electrical connector (1).

2. Remove mounting bolt and remove capacitor.

INSTALLATION

IGNITION COIL CAPACITOR



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Fig. 30: Ignition Coil Capacitor - Right Side Courtesy of CHRYSLER LLC

1. Install capacitor and tighten nut.

2. Attach electrical connector to capacitor.

3. Install the negative battery cable.

IGNITION COIL CAPACITOR - 6.1L



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Fig. 31: Capacitor - 6.1L Courtesy of CHRYSLER LLC

1. Install ignition capacitor (2) to engine.


3. Install electrical connector (1).

SWITCH - IGNITION

REMOVAL

IGNITION SWITCH

The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder. For ignition switch terminal and circuit identification, refer to appropriate SYSTEM WIRING DIAGRAMS .



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1. Disconnect negative cable from battery.

Fig. 32: Removing/Installing Instrument Panel Center Bezel Courtesy of CHRYSLER LLC

2. Remove the Instrument Panel Center Bezel. Refer to REMOVAL for Chrysler and refer to REMOVAL for Dodge.



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Fig. 33: Bezel Cluster Removed Courtesy of CHRYSLER LLC

3. Bezel cluster removed.



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Fig. 34: Trim Panel Courtesy of CHRYSLER LLC

4. Remove side trim panel to steering column cover.



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Fig. 35: Reinforcement Steering Column Courtesy of CHRYSLER LLC



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Fig. 36: Reinforcement Steering Column Removed Courtesy of CHRYSLER LLC

5. Remove the screws that secure the steering column cover to the instrument panel and relocate panel.

6. Pull the steering column cover rearward at the top and right side of the cover to release the snap retainers from the instrument panel.

7. Remove the screws that secure the instrument panel steering column cover reinforcement to bracket and remove reinforcement from the vehicle.



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Fig. 37: Removing Nuts At Ignition Switch Assembly Courtesy of CHRYSLER LLC

8. Remove the 2 front mounting nuts.



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Fig. 38: Switch Mounting Lower Nut Courtesy of CHRYSLER LLC

9. Remove the lower mounting nut.



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Fig. 39: SKREEM Module Courtesy of CHRYSLER LLC

10. Slide the assembly rearward into the instrument panel and down to gain access to switch.

1 - SKREEM Module2 - Ignition Switch



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Fig. 40: Switch Module Connector Connected Courtesy of CHRYSLER LLC



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Fig. 41: Switch Module Connector Disconnected Courtesy of CHRYSLER LLC

11. Disconnect the electrical connector from the ignition Switch and SKREEM Module.



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Fig. 42: Interlock Cable Retaining Tab Courtesy of CHRYSLER LLC

12. Remove the interlock cable by depressing the locking tab and pulling straight out. See Fig. 42.

1 - Retaining Tab for Cable



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Fig. 43: Interlock Cable Courtesy of CHRYSLER LLC

13. Interlocking cable removed. See Fig. 43.



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Fig. 44: Ignition Key Housing & Switch Courtesy of CHRYSLER LLC

14. Remove ignition switch mounting screw. See Fig. 44.

15. Squeeze the 2 locking tabs to remove ignition switch from the lock housing. See Fig. 44.

INSTALLATION

IGNITION SWITCH

1 - Ignition Key Housing2 - Ignition Switch3 - Ignition Switch Mounting Screws4 - Locking Tabs



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The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder. For ignition switch terminal and circuit identification, refer to SYSTEM WIRING DIAGRAMS .

Fig. 45: Ignition Switch Assembly Courtesy of CHRYSLER LLC

1. A tab on the ignition switch indexes to a notch in the lock cylinder housing. Also, a slot in the end of the ignition switch fits over the shaft in the end of the lock cylinder housing. Use the ignition key to rotate the lock cylinder to align the ignition switch with lock cylinder housing. Insert ignition switch into lock housing until locking tabs are seated into openings on lock housing.

1 - Switch Assembly2 - Rear Mounting Nut3 - Interlock Cable



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2. Install ignition switch mounting screw.

Fig. 46: Interlock Cable Retaining Tab Courtesy of CHRYSLER LLC

1 - Retaining Tab for Cable



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Fig. 47: Interlock Cable Courtesy of CHRYSLER LLC

3. Install the interlock cable into the switch assembly.



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Fig. 48: Module Connector Removed Courtesy of CHRYSLER LLC

4. Attach electrical connector to SKREEM Module.



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Fig. 49: Switch Module Connector Disconnected Courtesy of CHRYSLER LLC

5. Install switch assembly into Instrument Panel.



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Fig. 50: Switch Module Connector Connected Courtesy of CHRYSLER LLC

6. Attach electrical connector to ignition switch.



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Fig. 51: Removing Nuts at Ignition Switch Assembly Courtesy of CHRYSLER LLC

7. Tighten the 2 mounting nuts.



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Fig. 52: Switch Mounting Lower Nut Courtesy of CHRYSLER LLC

8. Tighten the lower mounting nut.



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Fig. 53: Reinforcement Steering Column Removed Courtesy of CHRYSLER LLC

9. Install steering column reinforcement.



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Fig. 54: Reinforcement Steering Column Courtesy of CHRYSLER LLC

10. Steering column reinforcement installed.



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Fig. 55: Trim Panel Courtesy of CHRYSLER LLC

11. Install the Steering column reinforcement cover.

12. Install trim panel end.



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Fig. 56: Removing/Installing Instrument Panel Center Bezel Courtesy of CHRYSLER LLC

13. Install the Bezel cluster.



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Fig. 57: Switch Bezel Courtesy of CHRYSLER LLC

14. Install the ignition switch bezel ring.

15. Connect the negative battery cable.

CYLINDER - IGNITION KEY AND LOCK

REMOVAL

IGNITION KEY AND LOCK CYLINDER



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Fig. 58: Tab Location With Bezel In Place Courtesy of CHRYSLER LLC

1. Disconnect the negative battery cable.

2. Remove bezel ignition switch ring.

3. Pull center console bezel loose from instrument panel.



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Fig. 59: Depressing Tab Without Bezel Courtesy of CHRYSLER LLC

4. Insert ignition key and turn to the "ON" position.

5. Depress the locking tab on the ignition switch housing.



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Fig. 60: Removing/Installing Key Cylinder Courtesy of CHRYSLER LLC

6. Pull the key cylinder from the ignition switch housing.

INSTALLATION

IGNITION KEY AND LOCK CYLINDER

1 - Locking Tab Location



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Fig. 61: Removing/Installing Key Cylinder Courtesy of CHRYSLER LLC

1. Install key in lock cylinder. Turn key to "ON" position (retaining tab on lock cylinder can be depressed).

2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the "ON" position.

3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing.

1 - Locking Tab Location



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Fig. 62: Depressing Tab Without Bezel Courtesy of CHRYSLER LLC

4. Turn key to Off position and remove key.



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Fig. 63: Tab Location With Bezel In Place Courtesy of CHRYSLER LLC

5. Install center console bezel to instrument panel.

6. Install bezel ignition switch ring.


SENSOR - KNOCK

REMOVAL

KNOCK SENSOR - 2.7L



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Fig. 64: Locating Knock Sensor - 2.7L Courtesy of CHRYSLER LLC


The sensors screws into the cylinder block, directly below the intake manifold.

2. Remove intake manifold. Refer to REMOVAL .

3. Remove the passenger side cylinder head, refer to REMOVAL .

4. Disconnect electrical connector from knock sensor.

5. Use a crows foot socket to remove the knock sensors.

KNOCK SENSOR - 3.5L



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Fig. 65: Knock Sensor Connector Courtesy of CHRYSLER LLC


2. Remove the upper intake manifold. Refer to REMOVAL .

3. Disconnect the electrical connector.



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4. Remove the knock sensor.

KNOCK SENSOR - 5.7L



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Two sensors (1) are used. Each sensor is bolted to the outside of cylinder block below the exhaust manifold (3).

1. Raise vehicle.

2. Disconnect knock sensor electrical connector (5).

3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.

4. Remove sensor from engine.

KNOCK SENSOR - 6.1L



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Two knock sensors (1) are used. Each sensor is bolted to the outside of cylinder block below the exhaust manifold (3).

1. Raise vehicle.



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Fig. 69: Knock Sensor Heat Shield - 6.1L Courtesy of CHRYSLER LLC

2. Remove heat shield (1) from knock sensor. Shield snaps to sensor.



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Fig. 70: Locating Knock Sensor Courtesy of CHRYSLER LLC

3. Disconnect knock sensor electrical connector (5).

4. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.

5. Remove sensor from engine.

INSTALLATION

KNOCK SENSOR - 2.7L



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The sensors screws into the cylinder block, directly below the intake manifold.

1. Install knock sensor. Tighten knock sensor to 10 N.m (7 ft. lbs.) torque. Over or under tightening effects knock sensor performance resulting in possible improper spark control.

2. Attach electrical connector to knock sensor.

3. Install the passenger side cylinder head. Refer to INSTALLATION .

4. Install intake manifold. Refer to INSTALLATION .


KNOCK SENSOR - 3.5L



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1. Install knock sensor. Tighten knock sensor to 20 N.m (15 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control.



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Fig. 73: Knock Sensor Wire Route Courtesy of CHRYSLER LLC

2. Route the knock sensor wire in the proper location.




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Fig. 74: Knock Sensor Connector Courtesy of CHRYSLER LLC

4. Connect electrical connector. See Fig. 74.


KNOCK SENSOR - 5.7L



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1. Thoroughly clean knock sensor mounting hole.

2. Install sensor (1) into cylinder block.

NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8mm bolt.

NOTE: The foam strip used on bolt threads is used only to retain the bolts to



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3. Install and tighten mounting bolt (2) to 20 N.m (15 ft. lbs.) torque.

4. Install electrical connector to sensor.

KNOCK SENSOR - 6.1L


1. Thoroughly clean knock sensor mounting hole.

2. Install sensor (1) onto cylinder block.

sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.



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3. Install and tighten mounting bolt (2) to 20 N.m (15 ft. lbs.) torque.

4. Install electrical connector (5) to sensor.

Fig. 77: Knock Sensor Heat Shield - 6.1L Courtesy of CHRYSLER LLC

NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8mm bolt.

NOTE: The foam strip used on bolt threads is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.



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5. Install heat shield (1) to sensor (shield snaps on).

PLUG - GLOW

DESCRIPTION

GLOW PLUG

Fig. 78: Glow Plug Courtesy of CHRYSLER LLC

Glow plugs are used to help start a cold or cool engine. See Fig. 78. The glow plugs will heat up and glow to heat the combustion chamber of each cylinder. An individual glow plug is used for each cylinder. Each glow plug is threaded into the side of the cylinder head below the cylinder head cover.

OPERATION

GLOW PLUG

The glow plugs are used to preheat the combustion chambers in order to achieve the ignition temperature required for the fuel-air mixture.

The glow plug consists of a housing with a female thread and an interference-fit rod. The heating element is integrated in the glow rod. It consists of a heating winding and a control winding connected in series.



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When the glow plug system is switched "ON", a current of about 30 ampere flows to each glow plug. The heating winding heats the glow plug. The control winding increases its resistance as the temperature rises and limits the current to approximately 15-25 ampere. The glow plug is protected this way from overloads.

REMOVAL

GLOW PLUG


2. Remove engine cover. Refer to REMOVAL .

3. Disconnect glow plug electrical connector (1).

4. Clean glow plug bay.

5. Remove glow plugs.

INSTALLATION

GLOW PLUG

1. Install glow plug. Tighten glow plugs to 12 Nm (106 lbs. in.).

2. Connect glow plug electrical connector (1).

3. Install engine cover. Refer to INSTALLATION .


PLUG - SPARK

DESCRIPTION

SPARK PLUGS PLATINUM

The V6 engines use platinum resistor spark plugs. They have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. For spark plug identification and specifications, Refer to the Specifications section.

Do not use an ohmmeter to check the resistance of the spark plugs. This will give an inaccurate reading.

When the spark plugs use a single or double platinum tips and they have a recommended service life of 100,000 miles for normal driving conditions per schedule A in this manual. The spark plugs have a recommended

CAUTION: Engine temperature must be at least 90°C (194°F) before removing glow plugs. If cylinder head is already removed, warm cylinder head to 90°C (194°F) before removing glow plugs.

WARNING: Risk of injury to skin and eyes from handling hot or glowing objects. Wear protective gloves, clothing and eye wear.



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service life of 75,000 miles for severe driving conditions per schedule B in this manual. A thin platinum pad is welded to both or just the center electrode end(s). See Fig. 79. Extreme care must be used to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. See Fig. 80.

Fig. 79: Platinum Pads Courtesy of CHRYSLER LLC

1 - APPLY ANTI-SEIZE COMPOUND HERE ONLY2 - PLATINUM SPARK SURFACE

CAUTION: Cleaning of the platinum plug may damage the platinum tip.



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Fig. 80: Setting Spark Plug Electrode Gap Courtesy of CHRYSLER LLC



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REMOVAL

SPARK PLUG - 2.7L


Always remove the ignition coil assembly by grasping at the spark plug boot, turning the assembly 1/2 turn and pulling straight back in a steady motion.



3. Prior to removing the ignition coils, spray compressed air around the coil area and spark plug to remove contaminates from around spark plug tube.

1 - TAPER GAUGE



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4. Remove the ignition coils.

5. Remove the spark plug using a quality socket with a rubber or foam insert.

6. Inspect the spark plug condition.

SPARK PLUG - 3.5L


Always remove the ignition coil assembly by grasping at the spark plug boot, turning the assembly 1/2 turn and pulling straight back in a steady motion.





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3. Prior to removing the ignition coils, spray compressed air around the coil area and spark plug to remove contaminates from around spark plug tube.


4. Remove the ignitions coil.

5. Remove the spark plug using a quality socket with a rubber or foam insert.

6. Inspect the spark plug condition.

SPARK PLUG - 5.7L/6.1L

Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to IGNITION COIL - 5.7/6.1L.

1. Remove necessary air filter tubing at throttle body.

2. Prior to removing ignition coil, spray compressed air around coil base at cylinder head.

3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber.

4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. Also check condition of ignition coil O-ring and replace as necessary.

5. Inspect spark plug condition.

INSTALLATION

SPARK PLUG - 2.7L



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1. To avoid cross threading, start the spark plug into the cylinder head by hand.

2. Tighten spark plugs. Tighten to 17 N.m (12.5 ft. lbs.).

3. Install ignition coil assembly onto spark plug.

4. Hand tighten coil screws.

5. Tighten ignition coil screws to 6.7 N.m (60 in. lbs.).

6. Connect and lock the electrical connector.



SPARK PLUG - 3.5L



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1. To avoid cross threading, start the spark plug into the cylinder head by hand.

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

3. Install ignition coil assembly onto spark plug.

4. Hand tighten coil screws.

5. Tighten ignition coil screws to 6.7 N.m (60 in. lbs.).

6. Connect and lock the electrical connector.



SPARK PLUG - 5.7L/6.1L

Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged.



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Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator.

1. Start the spark plug into the cylinder head by hand to avoid cross threading.

2. Tighten 5.7L spark plugs to 18 N.m (13 ft. lbs.) torque. Tighten 6.1L spark plugs to 15-20 N.m (11-15 ft. lbs.) torque.

3. Before installing ignition coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring.

4. Install ignition coil(s). Refer to IGNITION COIL - 5.7/6.1L.



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ignition system - service information - story time with keith

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