Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 200
IGNITION COIL
The 2.5L and 3.0L engines use an epoxy type coil.
The coils are not oil filled. The windings are embedded
in a heat and vibration resistant epoxy compound.
The engine controller operates the ignition coil
through the auto shutdown (ASD) relay. When the
relay is energized by the engine controller, battery
voltage is connected to the ignition coil positive termi-
nal. The engine controller will de-energize the ASD
relay if it does not receive an input from the distributor
pick-up. Refer to Auto Shutdown (ASD) Relay and Fuel
Pump Relay in this section.
On 2.5L engines the ignition coil is mounted to the
thermostat housing (Fig. 23). On 3.0L engines the coil
is mounted on the rear of the intake manifold next to
the air cleaner (Fig. 24).
Fig. 22 Auto Shutdown Relay and Fuel Pump Relay
Fig. 23 Ignition Coil—2.5L Engine
Fig. 24 Ignition Coil—3.0L Engine
.
IGNITION SYSTEMS
8D - 9
2.5L AND 3.0L IGNITION SYSTEMS—DIAGNOSTIC PROCEDURES
INDEX
page
page
Coolant Temperature Sensor Test
. . . . . . . . . . . . . 12
Failure to Start Test—2.5L TBI and 3.0L Engines
. . 11
General Information
. . . . . . . . . . . . . . . . . . . . . . . 10
Ignition Coil
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Manifold Absolute Pressure (MAP) Sensor Test
. . . 12
Poor Performance Test
. . . . . . . . . . . . . . . . . . . . . 12
Spark Plugs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Testing for Spark at Coil
. . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
For additional information, refer to On Board Diag-
nostics in the Fuel Injection General Diagnosis sec-
tions of Group 14.
SPARK PLUGS
Faulty or fouled spark plugs may perform well at idle
speed, but frequently fail at higher engine speeds.
Faulty plugs can be identified in a number of ways:
poor fuel economy, power loss, decrease in engine
speed, hard starting and, in general, poor engine
performance.
Spark plugs also malfunction because of carbon foul-
ing, excessive electrode air gap, or a broken insulator.
Refer to the General Information Section of this group
for spark plug diagnosis.
IGNITION COIL
The ignition coil is designed to operate without an
external ballast resistor.
Inspect the coil for arcing. Test the coil according to
coil tester manufacturer’s instructions. Test coil pri-
mary and secondary resistance. Replace any coil that
does not meet specifications. Refer to the Coil Resis-
tance chart.
If the ignition coil is replaced due to a burned tower,
carbon tracking, arcing at the tower, or damage to the
terminal or boot on the coil end of the secondary cable,
the cable must be replaced. Arcing at the tower will
carbonize the nipple which, if it is connected to a new
coil, will cause the coil to fail.
If a secondary cable shows any signs of damage, the
cable should be replaced with a new cable and new
terminal. Carbon tracking on the old cable can cause
arcing and the failure of a new coil.
TESTING FOR SPARK AT COIL
WARNING: APPLY PARKING BRAKE AND/OR BLOCK
THE WHEELS BEFORE PERFORMING ANY TEST
WITH THE ENGINE RUNNING.
CAUTION: Spark plug cables may be damaged if this
test is performed with more than 1/4 inch clearance
between the cable and engine ground.
Remove the coil secondary cable from the distributor
cap. Hold the end of cable about 6 mm (1/4-inch) away
from a good engine ground (Fig. 1). Crank the engine
and inspect for spark at the coil secondary cable.
There must be a constant spark at the coil secondary
cable. If the spark is constant, have a helper continue
to crank engine and, while slowly moving coil second-
ary cable away from ground, look for arcing at the coil
tower. If arcing occurs at the tower, replace the coil. If
spark is not constant or there is no spark, proceed to
the failure to start test.
If a constant spark is present and no arcing occurs at
the coil tower, the ignition system is producing the
necessary high secondary voltage. However, make sure
that the spark plugs are firing. Inspect the distributor
rotor, cap, spark plug cables, and spark plugs. If they
are in proper working order, the
COIL RESISTANCE
8D - 10
IGNITION SYSTEMS
.
ignition system is not the reason why the engine will
not start. Inspect the fuel system and engine for proper
operation.
FAILURE TO START TEST—2.5L TBI AND 3.0L
ENGINES
Before proceeding with this test make sure
Testing For Spark At Coil has been performed.
Failure to do this may lead to unnecessary diag-
nostic time and wrong test results.
WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
ANY TEST WITH THE ENGINE RUNNING.
(1) Battery voltage must be at least 12.4 volts to
perform test.
(2) Crank the engine for 5 seconds while monitoring
the voltage at the coil positive (+) terminal (Fig. 2 or
Fig. 3). If the voltage remains near zero during the
entire period of cranking, refer to Group 14 for On-
Board Diagnostic checks. These checks will help diag-
nose problems with the engine controller and auto
shutdown relay.
(3) If voltage is at near-battery voltage and drops to
zero after 1-2 seconds of cranking, see Group 14 for
On-Board Diagnostic check for the distributor refer-
ence pickup circuit to the engine controller.
(4) If voltage remains at near battery voltage during
the entire 5 seconds, with the key off, remove the
engine controller 60-way connector. Check the 60-way
connector for any terminals that are pushed out or
loose.
(5) Remove the connector to coil (+) and connect a
jumper wire between battery (+) and coil (+).
(6) Using the special jumper (Fig. 4), momentarily
ground terminal #19 of the 60-way connector (Fig. 5). A
spark should be generated when the ground is re-
moved.
Fig. 1 Checking for Spark
Fig. 2 Coil Terminals—2.5L Engines
Fig. 3 Coil Terminals—3.0L Engine
Fig. 4 Special Jumper to Ground Coil Negative
Fig. 5 60-Way Electrical Connector, Engine Control-
ler
.
IGNITION SYSTEMS
8D - 11
(7) If spark is generated, replace the engine control-
ler.
(8) If no spark is seen, use the special jumper to
ground the coil (-) terminal directly.
(9) If spark is produced, inspect wiring harness for
an open condition.
(10) If no spark is produced, replace the ignition coil.
POOR PERFORMANCE TEST
To prevent unnecessary diagnostic time and
possible incorrect results, the Testing For Spark
At Coil procedure should be performed before
this test.
WARNING: APPLY PARKING BRAKE AND/OR BLOCK
THE WHEELS BEFORE PERFORMING ANY ENGINE
RUNNING TESTS.
Check and adjust basic timing (refer to the specifica-
tion section of this group and see service procedures).
Refer to Group 14, General Diagnosis On Board
Diagnostics.
COOLANT TEMPERATURE SENSOR TEST
(1) With key off, disconnect wire connector from
coolant temperature sensor (Fig. 6).
(2) Connect one lead of ohmmeter to one terminal of
coolant temperature sensor.
(3) Connect the other lead of ohmmeter to remaining
connector of coolant temperature sensor. The ohmme-
ter should read as follows;
• Engine/Sensor at normal operating temperature
around 200°F should read approximately 700 to 1,000
ohms.
• Engine/Sensor at room temperature around 70°F,
ohmmeter should read approximately 7,000 to 13,000
ohms.
• See On Board Diagnostics in the General
Diagnosis section of Group 14, or refer to the
appropriate diagnostic manual for further test
procedures.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
TEST
Refer to Board Diagnostics in the Fuel Injection
General Diagnosis sections of Group 14, or the appro-
priate Powertrain Diagnostic Procedures manual for
further test procedures.
Fig. 6 Coolant Temperature Sensor Test
8D - 12
IGNITION SYSTEMS
.
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