Chrysler Stratus Convertible. Manual — part 235
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.
NOTE: Over or under tightening affects knock sen-
sor performance, possibly causing improper spark
control.
LOCK KEY CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 9) :
• Accessory
• Off (lock)
• Unlock
• On/Run
• Start
IGNITION INTERLOCK
OPERATION
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Off, Run or Start position. In addi-
tion, the operator cannot rotate the key to the lock
position unless the shifter is in the park position. On
vehicles equipped with floor shift refer to the - Tran-
saxle for Automatic Transmission Shifter/Ignition
Interlock.
REMOVAL AND INSTALLATION
SPARK PLUGS AND CABLES—2.5L
When replacing the spark plug and coil 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.
CAUTION: Never attempt to file the electrodes or
use a wire brush for cleaning platinum plugs. This
would damage the platinum pads which would
shorten spark plug life.
Never force a gap gauge between the platinum
electrodes or adjust the gap on platinum spark plugs
without reading the 2.5L Spark Plug Gap Measure-
ment procedures below.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap. Overtightening can
also damage the cylinder head. Tighten spark plugs
to 28 N·m (20 ft. lbs.) torque.
Due to the engine packaging environment for the
2.5L engines, extreme care should be used when
installing the spark plugs to avoid cross threading
problems.
2.5L SPARK PLUG GAP MEASUREMENT
CAUTION: The Platinum pads can be damaged dur-
ing the measurement of checking the gap if extreme
care is not used.
• Use only a taper gap gauge (Fig. 2)
• Never force the gap gauge through the platinum
pads. Only apply enough force until resistance is felt.
• Never use a wire brush or spark plug cleaner
machine to clean platinum spark plugs
• Use an OSHA approved air nozzle when drying
gas fouled spark plugs.
If gap adjustment is required of platinum plug,
bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool
and check with a taper gap gauge (Fig. 1).
Apply a very small amount of anti-seize compound
to the threads when reinstalling the vehicle’s original
spark plugs that have been determined good. Do not
apply anti-seize compound to new spark plugs.
Fig. 9 Ignition Lock Cylinder Detents
JX
IGNITION SYSTEM
8D - 5
DESCRIPTION AND OPERATION (Continued)
NOTE: Anti-seize compound is electrically conduc-
tive and can cause engine misfires if not applied
correctly. It is extremely important that the anti-
seize compound doesn’t make contact with the
spark plug electrodes or ceramic insulator.
SPARK PLUG REMOVAL—#2, #4 or #6
Always remove the ignition cable by grasping at
the spark plug boot turning, 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 rubber or foam insert.
(3) Inspect the spark plug condition. Refer to
Spark Plug Condition in this section.
INSTALLATION
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 N·m (20 ft. lbs.) torque.
(3) Install ignition cables over spark plugs.
SPARK PLUG REMOVAL—#1, #3 or #5
(1) Disconnect
negative
cable
from
auxiliary
jumper terminal.
(2) Remove the intake manifold, refer to the
Engine Section for the procedure.
(3) Always remove the ignition cable by grasping
at the spark plug boot turning, the boot 1/2 turn and
pulling straight back in a steady motion.
(4) Prior to removing the spark plug spray com-
pressed air around the spark plug hole and the area
around the spark plug.
(5) Remove the spark plug using a quality socket
with a rubber or foam insert.
(6) Inspect the spark plug condition. Refer to
Spark Plug Condition in this section.
SPARK PLUG INSTALLATION
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 N·m (20 ft. lbs.)
torque.
(3) Install ignition cables over spark plugs.
(4) Install the intake manifold, refer to the Engine
section
(5) Tighten air inlet tube clamps to 3 N·m
61 (25
65 in. lbs.) torque.
(6) Connect negative terminal to auxiliary jumper
terminal.
IGNITION COIL—2.5L
The ignition coil is located in the distributor hous-
ing (Fig. 10).
If ignition coil is defective, replace distributor
assembly. Refer to Distributor Service.
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
ter (PDC) (Fig. 11). The PDC is located in the engine
compartment. For the location of the relay within the
PDC, refer to the PDC cover for location. Check elec-
trical terminals for corrosion and repair as necessary.
CRANKSHAFT POSITION SENSOR—2.5L
REMOVAL
(1) Remove speed control servo from driver’s side
strut tower.
(2) Remove crankshaft position sensor retaining
bolt (Fig. 12).
(3) Pull crankshaft position sensor straight up out
of the transaxle housing.
(4) (Disconnect crankshaft position sensor electri-
cal connector from the wiring harness connector.
Fig. 10 Ignition Coil
1 – IGNITION COIL
2 – COIL TOWER
3 – DISTRIBUTOR HOUSING
8D - 6
IGNITION SYSTEM
JX
REMOVAL AND INSTALLATION (Continued)
INSTALLATION—ADJUSTABLE
All vehicles will be equipped with an adjustable
crankshaft position sensor. This can be identified by
an elongated mounting hole in the sensor.
NOTE: If the removed sensor is to be reinstalled,
clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the sensor face before
installation. If the sensor is being replaced, confirm
that the paper spacer is attached to the face of the
new sensor (Fig. 13).
(1) Install sensor in transaxle and push sensor
down until contact is made with the drive plate.
While holding the sensor in this position, install and
tighten the retaining bolt to 12 N·m (105 in. lbs.)
torque.
(2) Connect crankshaft position sensor electrical
connector to the wiring harness connector.
(3) Attach connector to heater tube bracket.
(4) Install speed control servo. Tighten nuts to 9
N·m (80 in. lbs.) torque.
DISTRIBUTOR—2.5L
REMOVAL
(1) Remove bolt holding air inlet resonator to
intake manifold.
(2) Loosen clamps holding air cleaner cover to air
cleaner housing.
(3) Remove PCV make-up air hose from air inlet
tube.
(4) Loosen hose clamp at throttle body.
(5) Remove air inlet tube, resonator and air
cleaner cover.
(6) Remove EGR tube.
(7) Remove spark plug cables from distributor cap.
(8) Loosen distributor cap holddown screws and
remove cap (Fig. 14).
Fig. 11 Power Distribution Center (PDC)
1 – BATTERY POSITIVE
2 – BATTERY GROUND
3 – AIR CLEANER
4 – PCM
5 – PDC
6 – TCM
Fig. 12 Crankshaft Position Sensor
1 – DISTRIBUTOR
2 – HOLD DOWN BOLT
3 – CRANKSHAFT POSITION SENSOR
Fig. 13 Crankshaft Position Sensor and Spacer
1 – PUSH ON CLIP
2 – CRANKSHAFT POSITION SENSOR
3 – PAPER SPACER
4 – ADJUSTMENT HOLE
JX
IGNITION SYSTEM
8D - 7
REMOVAL AND INSTALLATION (Continued)
(9) Mark the rotor position and remove rotor. The
mark indicates where to position the rotor when rein-
stalling the distributor.
(10) Remove 2 harness connectors from distributor
(Fig. 15).
(11) Remove 2 sets of distributor holddown nuts
and washers from studs.
(12) Remove bolt and spark plug cable mounting
bracket from top of distributor housing.
(13) Remove bolt and transmission dipstick tube.
(14) Carefully remove distributor from engine.
INSTALLATION
(1) Install rotor on shaft.
(2) Position distributor in engine. Make certain
that O-ring is properly seated on distributor. If
O-ring is cracked or nicked replace with a new one.
(3) Carefully engage distributor drive with slotted
end of camshaft. When the distributor is installed
properly, the rotor will be in line with previously
scribe line on air intake plenum. If engine was
cranked while distributor was removed, estab-
lish proper relationship between the distribu-
tor shaft and Number 1 piston position as
follows:
(a) Rotate the crankshaft until number one pis-
ton is at top of compression stroke.
(b) Rotate rotor to number one rotor terminal.
(c) Lower distributor into opening, engaging dis-
tributor drive with drive on camshaft. With distrib-
utor fully seated on engine, rotor should be under
the number 1 terminal.
(4) Install distributor holddown washers and nuts.
Tighten nuts to 13 N·m (9 ft. lbs.).
(5) Install spark plug cable bracket.
(6) Install 2 harness connectors to distributor.
(7) Install distributor cap.
(8) Install spark plug cables onto distributor cap.
The cap is numbered as well as the cables. Ensure
sure all high tension wires are firmly in the cap tow-
ers.
(9) Install transmission dispstick tube.
(10) Install EGR tube to intake manifold. Tighten
bolts to 11 N·m (95 in. lbs.) torque.
(11) Install air inlet tube, resonator and air
cleaner cover.
(12) Tighten hose clamp at throttle body.
(13) Install PCV make-up air hose from air inlet
tube.
(14) Tighten clamps holding air cleaner cover to
air cleaner housing.
(15) Install bolt holding air inlet resonator to
intake manifold.
Fig. 14 Distributor Cap Screws
1 – DISTRIBUTOR CAP SCREWS
Fig. 15 Distributor Electrical Connectors—Viewed
From Rear of Distributor
1 – SPARK PLUG CABLES
2 – DISTRIBUTOR CONNECTORS
8D - 8
IGNITION SYSTEM
JX
REMOVAL AND INSTALLATION (Continued)
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