Dodge Durango (DN). Manual — part 274

(3) Remove spark plug from cylinder head using a

quality socket with a rubber or foam insert. If
equipped with a 4.7L V-8 engine, also check condition
of coil o-ring and replace as necessary.

(4) Except 4.7L: Always remove spark plug or igni-

tion coil cables by grasping at the cable boot (Fig.
20). Turn the cable boot 1/2 turn and pull straight
back in a steady motion. Never pull directly on the
cable. Internal damage to cable will result.

(5) Inspect spark plug condition. Refer to Spark

Plug Conditions.

CLEANING

The plugs may be cleaned using commercially

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

CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.

GAP ADJUSTMENT

Check the spark plug gap with a gap gauge tool. If

the gap is not correct, adjust it by bending the
ground electrode (Fig. 23). Never attempt to adjust
the gap by bending the center electrode.

INSTALLATION

CAUTION: The 4.7L V–8 engine is equipped with
copper core ground electrode spark plugs. They
must be replaced with the same type/number spark
plug as the original. If another spark plug is substi-
tuted, pre-ignition will result.

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 elec-
trodes can be damaged.

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.

Except 4.7L Engine: When replacing the spark

plug and ignition coil cables, route the cables cor-
rectly and secure them in the appropriate retainers.
Failure to route the cables properly can cause the
radio to reproduce ignition noise. 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 by

hand to avoid cross threading.

(2) Except 4.7L Engine: Tighten spark plugs to

35-41 N·m (26-30 ft. lbs.) torque.

(3) Except 4.7L Engine: Install spark plug cables

over spark plugs.

(4) 4.7L V–8 Engine: Tighten spark plugs to 27

N·m (20 ft. lbs.) torque.

(5) 4.7L V–8 Engine: Before installing coil(s),

check condition of coil o-ring and replace as neces-
sary. To aid in coil installation, apply silicone to coil
o-ring.

(6) 4.7L V–8 Engine: Install ignition coil(s). Refer

to Ignition Coil Removal/Installation.

IGNITION COIL—3.9/5.2/5.9L ENGINES

The ignition coil is an epoxy filled type. If the coil

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

REMOVAL

The coil is mounted to a bracket that is bolted to

the front of the right engine cylinder head (Fig. 24).
This bracket is mounted on top of the automatic belt
tensioner bracket using common bolts.

(1) Disconnect the primary wiring from the igni-

tion coil.

(2) Disconnect the secondary spark plug cable from

the ignition coil.

Fig. 23 Setting Spark Plug Gap—Typical

1 – GAUGE
2 – SPARK PLUG

8D - 12

IGNITION SYSTEM

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REMOVAL AND INSTALLATION (Continued)

WARNING: DO NOT REMOVE THE COIL MOUNTING
BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS.
THE COIL MOUNTING BRACKET IS UNDER ACCES-
SORY DRIVE BELT TENSION. IF THIS BRACKET IS
TO BE REMOVED FOR ANY REASON, ALL BELT
TENSION MUST FIRST BE RELIEVED. REFER TO
THE BELT SECTION OF GROUP 7, COOLING SYS-
TEM.

(3) Remove

ignition

coil

from

coil

mounting

bracket (two bolts).

INSTALLATION

(1) Install the ignition coil to coil bracket. If nuts

and bolts are used to secure coil to coil bracket,
tighten to 11 N·m (100 in. lbs.) torque. If the coil
mounting bracket has been tapped for coil mounting
bolts, tighten bolts to 5 N·m (50 in. lbs.) torque.

(2) Connect all wiring to ignition coil.

IGNITION COIL—4.7L ENGINE

REMOVAL

An individual ignition coil is used for each spark

plug (Fig. 25). The coil fits into machined holes in the
cylinder head. A mounting stud/nut secures each coil
to the top of the intake manifold (Fig. 26). The bot-
tom of the coil is equipped with a rubber boot to seal
the spark plug to the coil. Inside each rubber boot is
a spring. The spring is used for a mechanical contact
between the coil and the top of the spark plug. These
rubber boots and springs are a permanent part of the
coil and are not serviced separately. An o-ring (Fig.

25) is used to seal the coil at the opening into the cyl-
inder head.

(1) Depending on which coil is being removed, the

throttle body air intake tube or intake box may need
to be removed to gain access to coil.

(2) Disconnect electrical connector (Fig. 26) from

coil by pushing downward on release lock on top of
connector and pull connector from coil.

(3) Clean area at base of coil with compressed air

before removal.

(4) Remove coil mounting nut from mounting stud

(Fig. 26).

(5) Carefully pull up coil from cylinder head open-

ing with a slight twisting action.

(6) Remove coil from vehicle.

INSTALLATION

(1) Using compressed air, blow out any dirt or con-

taminants from around top of spark plug.

(2) Check condition of coil o-ring and replace as

necessary. To aid in coil installation, apply silicone to
coil o-ring.

(3) Position ignition coil into cylinder head opening

and push onto spark plug. Do this while guiding coil
base over mounting stud.

(4) Install mounting stud nut and tighten to 8 N·m

(70 in. lbs.) torque.

(5) Connect electrical connector to coil by snapping

into position.

(6) If necessary, install throttle body air tube or

box.

Fig. 24 Ignition Coil—3.9L V-6 or 5.2/5.9L V-8

Engines

1 – ACCESSORY DRIVE BELT TENSIONER
2 – COIL CONNECTOR
3 – IGNITION COIL
4 – COIL MOUNTING BOLTS

Fig. 25 Ignition Coil—4.7L V–8 Engine

1 – O-RING
2 – IGNITION COIL
3 – ELECTRICAL CONNECTOR

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IGNITION SYSTEM

8D - 13

REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT POSITION SENSOR—3.9/5.2/
5.9L ENGINES

REMOVAL

The sensor is bolted to the top of the cylinder block

near the rear of right cylinder head (Fig. 27). The
sensor is accessed by removing the right front fender
liner.

(1) Remove right front tire and right front wheel-

house liner. Refer to Front Wheelhouse Liner in
Group 23, Body.

(2) Disconnect crankshaft position sensor pigtail

harness from main wiring harness.

(3) Remove two sensor (recessed hex head) mount-

ing bolts (Fig. 27).

(4) Remove sensor from engine.

INSTALLATION

(1) Position crankshaft position sensor to engine.
(2) Install mounting bolts and tighten to 8 N·m (70

in. lbs.) torque.

(3) Connect main harness electrical connector to

sensor.

(4) Install right front tire and right front wheel-

house liner. Refer to Front Wheelhouse Liner in
Group 23, Body.

CRANKSHAFT POSITION SENSOR—4.7L V-8
ENGINE

REMOVAL

The Crankshaft Position (CKP) sensor is located at

the right-rear side of the engine cylinder block (Fig.
28). It is positioned and bolted into a machined hole
in the engine block.

(1) Disconnect CKP electrical connector at sensor.
(2) Remove CKP mounting bolt (Fig. 28).
(3) Carefully pry sensor from cylinder block in a

rocking action with two small screwdrivers.

(4) Remove sensor from vehicle.
(5) Check condition of sensor o-ring.

INSTALLATION

(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor

o-ring.

(3) Install sensor into engine block with a slight

rocking action. Do not twist sensor into position as
damage to o-ring may result.

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

Fig. 26 Ignition Coil Location—4.7L V–8 Engine

1 – IGNITION COIL
2 – COIL ELECTRICAL CONNECTOR
3 – COIL MOUNTING STUD/NUT

Fig. 27 Crankshaft Position Sensor—3.9/5.2/5.9L

Engines

1 – GROMMET
2 – MOUNTING BOLTS (2)
3 – CRANKSHAFT POSITION SENSOR
4 – RIGHT EXHAUST MANIFOLD
5 – TRANSMISSION BELL HOUSING

8D - 14

IGNITION SYSTEM

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REMOVAL AND INSTALLATION (Continued)

(4) Install mounting bolt and tighten to 28 N·m

(21 ft. lbs.) torque.

(5) Connect electrical connector to sensor.

CAMSHAFT POSITION SENSOR

The camshaft position sensor is located in the dis-

tributor on all 3.9L V-6 and 5.2/5.9L V-8 engines (Fig.
29).

REMOVAL

Distributor removal is not necessary to remove

camshaft position sensor.

(1) Remove air cleaner assembly.
(2) Disconnect negative cable from battery.
(3) Remove distributor cap from distributor (two

screws).

(4) Disconnect camshaft position sensor wiring

harness from main engine wiring harness.

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

from the distributor housing (Fig. 29).

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.

(5) Install air cleaner assembly.

CAMSHAFT POSITION SENSOR—4.7L ENGINE

The Camshaft Position Sensor (CMP) on the 4.7L

V–8 engine is bolted to the front/top of the right cyl-
inder head (Fig. 30).

Fig. 28 CKP Sensor Location/Removal/Installation—

4.7L V–8 Engine

1 – CRANKSHAFT POSITION SENSOR
2 – MOUNTING BOLT

Fig. 29 Camshaft Position Sensor

1 – SYNC SIGNAL GENERATOR
2 – CAMSHAFT POSITION SENSOR
3 – PULSE RING
4 – DISTRIBUTOR ASSEMBLY

Fig. 30 CMP Location—4.7L Engine

1 – RIGHT CYLINDER HEAD
2 – CAMSHAFT POSITION SENSOR
3 – MOUNTING BOLT
4 – ELEC. CONNECTOR

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IGNITION SYSTEM

8D - 15

REMOVAL AND INSTALLATION (Continued)