Chrysler RG Voyager. Manual — part 719

REMOVAL

REMOVAL - 2.4L

The electronic ignition coil pack attaches directly

to the valve cover.

(1) Diconnect the negative battery cable.
(2) Disconnect electrical connector from coil pack.
(3) Remove coil pack mounting bolts.

(4) Remove coil pack and heat shield (Fig. 9).

REMOVAL - 3.3/3.8L

(1) Disconnect the negative battery cable.
(2) Remove the throttle and speed control cables

from clip.

(3) Remove 2 bolts from the Power steering reser-

voir to intake manifold.

(4) Loosen the lower nut for the power steering

reservoir from stud on ignition coil bracket.

(5) Reposition the Power steering reservoir (Fig.

11).

(6) Remove the ignition cables from the ignition

coil.

(7) Disconnect the electrical connector from the

ignition coil.

(8) Remove 2 nuts from the ignition coil studs.

INSTALLATION

INSTALLATION - 2.4L

(1) Install ignition coil and heat shield to valve

cover and tighten bolts.

(2) Connect the electrical connector to the ignition

coil.

(3) Transfer spark plug cables to new coil pack.

The coil pack towers are numbered with the cylinder
identification. Be sure the ignition cables are fully
seated onto the towers.

(4) Connect the negative battery cable.

Fig. 9 IGNITION COIL - 2.4L

Fig. 10 IGNITION COIL - 3.3/3.8L

1 -Ignition Coil

Fig. 11 IGNITION COIL BRACKET 3.3/3.8L

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IGNITION CONTROL

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IGNITION COIL (Continued)

INSTALLATION - 3.3/3.8L

(1) Install coil over studs on bracket.
(2) Install 2 nuts to the ignition coil studs. Tighten

nuts and bolts.

(3) Connect the electrical connector to the ignition

coil.

(4) Install the ignition cables to the ignition coil.
(5) Reposition the Power steering reservoir. Slide

bracket over the mounting stud (Fig. 11).

(6) Install 2 bolts to the Power steering reservoir

to intake manifold.

(7) Tighten the lower nut to stud on ignition coil

bracket.

(8) Install the throttle and speed control cables to

clip.

(9) Connect the negative battery cable.

KNOCK SENSOR

DESCRIPTION

The knock sensor threads into the cylinder block.

The knock sensor is designed to detect engine vibra-
tion that is caused by detonation.

OPERATION

When the knock sensor detects a knock in one of

the cylinders, it sends an input signal to the PCM. In
response, the PCM retards ignition timing for all cyl-
inders by a scheduled amount.

Knock sensors contain a piezoelectric material

which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal’s vibration increases, the
knock sensor output voltage also increases.

The voltage signal produced by the knock sensor

increases with the amplitude of vibration. The PCM
receives as an input the knock sensor voltage signal.
If the signal rises above a predetermined level, the
PCM will store that value in memory and retard
ignition timing to reduce engine knock. If the knock
sensor voltage exceeds a preset value, the PCM
retards ignition timing for all cylinders. It is not a
selective cylinder retard.

The PCM ignores knock sensor input during engine

idle conditions. Once the engine speed exceeds a
specified value, knock retard is allowed.

Knock retard uses its own short term and long

term memory program.

Long term memory stores previous detonation

information in its battery-backed RAM. The maxi-
mum authority that long term memory has over tim-
ing retard can be calibrated.

Short term memory is allowed to retard timing up

to a preset amount under all operating conditions (as
long as rpm is above the minimum rpm) except WOT.

The PCM, using short term memory, can respond
quickly to retard timing when engine knock is
detected. Short term memory is lost any time the
ignition key is turned off.

NOTE: Over or under tightening affects knock sen-
sor performance, possibly causing improper spark
control.

REMOVAL

REMOVAL - 2.4L

The knock sensor threads into the side of the cyl-

inder block in front of the starter (Fig. 12).

(1) Disconnect electrical connector from knock sen-

sor.

(2) Use a crow foot socket to remove the knock

sensors.

REMOVAL - 3.8L

The knock sensor threads into the side of the cyl-

inder block in the rear.

(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) On All Wheel Drive vehicles remove the PTU

(Power Transfer Unit), refer to the Transmission sec-
tion for more information.

(4) Disconnect electrical connector from knock sen-

sor.

(5) Use a crow foot socket to remove the knock

sensor.

INSTALLATION

INSTALLATION - 2.4L

The knock sensor threads into the side of the cyl-

inder block in front of the starter (Fig. 12).

(1) Install knock sensor. Tighten knock sensor to

10 N·m (7 ft. lbs.) torque. Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.

(2) Attach electrical connector to knock sensor.

INSTALLATION - 3.8L

The knock sensor threads into the side of the cyl-

inder block in the rear.

(1) Install knock sensor. Tighten knock sensor to

10 N·m (7 ft. lbs.) torque. Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.

(2) Attach electrical connector to knock sensor.
(3) On All Wheel Drive vehicles install the PTU

(Power Transfer Unit) for the rear wheels, refer to
the Transmission section for more information.

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IGNITION CONTROL

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IGNITION COIL (Continued)

(4) Lower vehicle.
(5) Connect the negative cable.

SPARK PLUG

DESCRIPTION

DESCRIPTION - STANDARD 4 CYLINDER

All engines use resistor spark plugs. They have

resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.

Do not use an ohm meter to check the resis-

tance of the spark plugs. This will give an inac-
curate reading.

Refer to the Specifications section for gap and type

of spark plug.

DESCRIPTION - PLATINUM PLUGS

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 ohm meter to check the resis-

tance of the spark plugs. This will give an inac-
curate reading.

When the spark plugs use a single or double plat-

inum 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 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 cen-
ter electrode end(s) as shown in (Fig. 13). Extreme
care must be used to prevent spark plug cross
threading, mis-gapping (Fig. 14) and ceramic insula-
tor damage during plug removal and installation.

CAUTION: Cleaning of the platinum plug may dam-
age the platinum tip.

Fig. 12 Knock Sensor

1 - GENERATOR
2 - INTAKE MANIFOLD
3 - KNOCK SENSOR
4 - STARTER

Fig. 13 Platinum Pads

1 - APPLY ANTI-SEIZE COMPOUND HERE ONLY
2 - PLATINUM SPARK SURFACE

Fig. 14 Setting Spark Plug Electrode Gap

1 - TAPER GAUGE

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KNOCK SENSOR (Continued)

REMOVAL

When replacing the spark plugs and spark plug

cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs or short cir-
cuit the cables to ground.

Always remove cables by grasping at the boot,

rotating the boot 1/2 turn, and pulling straight back
in a steady motion.

(1) Prior to removing the spark plug, spray com-

pressed air around the spark plug hole and the area
around the spark plug.

(2) Remove the spark plug using a quality socket

with a foam insert.

(3) Inspect the spark plug condition.

INSTALLATION

When replacing the spark plugs and spark plug

cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs or short cir-
cuit the cables to ground.

(1) Coat threads of spark plug with anti-seize. Be

sure not to get anti-seize ANYWHERE BUT ON
THE THREADS OF THE SPARK PLUG as
shown in (Fig. 13).

(2) To avoid cross threading, start the spark plug

into the cylinder head by hand.

(3) Tighten spark plugs to 17.5 N·m (13 ft. lbs.)

torque.

(4) Install spark plug cables over spark plugs. A

click will be heard and felt when the cable properly
attaches to the spark plug.

SPARK PLUG CABLE

DESCRIPTION

Spark Plug cables are sometimes referred to as

secondary ignition wires. The wires transfer electri-
cal current from the ignition coil pack to individual

spark plugs at each cylinder. The resistive spark plug
cables are of nonmetallic construction. The cables
provide suppression of radio frequency emissions
from the ignition system.

Check the spark plug cable connections for good

contact at the coil, and spark plugs. Terminals should
be fully seated. The insulators should be in good con-
dition and should fit tightly on the coil, and spark
plugs. Spark plug cables with insulators that are
cracked or torn must be replaced.

Clean Spark Plug cables with a cloth moistened

with a non-flammable solvent. Wipe the cables dry.
Check for brittle or cracked insulation. The spark
plug cables and spark plug boots are made from high
temperature materials.

REMOVAL - 2.0/2.4L

Failure to route the cables properly could cause the

radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.

Remove spark plug cable from coil first.
Always remove the spark plug cable by grasping

the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.

INSTALLATION - 2.0/2.4L

Failure to route the cables properly could cause the

radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube, then connect the
other end to coil pack.

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SPARK PLUG (Continued)