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Ignition Control - Service Information Chrysler Town & Country V

Ignition System 17 illustrations ~2264 words

IGNITION SYSTEM

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).

The 3.3/3.8L engines use a distributorless ignition system and is commonly referred to as Direct Ignition System (DIS). The 4.0L engine uses a Coil on Plug design. The system's main components are the ignition coils, crankshaft position sensor, camshaft position sensor and spark plugs.

The crankshaft position sensor and camshaft position sensor are hall effect devices. The camshaft position sensor and crankshaft position sensor generate square wave 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.

IGNITION CABLE RESISTANCE

MINIMUMMAXIMUM
250 Ohms Per Inch750 Ohms Per Inch
3000 Ohms Per Foot9,000 Ohms Per Foot

IGNITION COIL RESISTANCE

MANUFACTUREREnginePrimary Resistance at 21°C-27°C (70°F-80°F)Secondary Resistance at 21°C-27°C (70°F-80°F)
Diamond Electric Mfg. Corporation3.3, 3.8L0.530 to 0.650 ohms10.9K to 14.7K ohms
Diamond Electric Mfg. Corporation4.0L0.495 to 0.605 ohms5.13K to 6.27K ohms

Scheme 6

Scheme 6: 3.3/3.8L
Scheme 6: 3.3/3.8L
1 - Electrical Connector

The firing order is 1-2-3-4-5-6.

Scheme 7

Scheme 7: 4.0L
Scheme 7: 4.0L

The firing order is 1-2-3-4-5-6.

SPECIFICATIONS - SPARK PLUGS

EngineSpark PlugElectrode GapThread Size
3.3/3.8LRE14PLP51.27 mm (0.050 in.)M14 X 1.25
4.0LZFR5LP-13G1.27 mm (0.050 in.)M14 X 1.25

SPECIFICATIONS - TORQUE

DESCRIPTIONN.mFt. Lbs.In. Lbs.
Camshaft Position Sensor Bolt 2.8L5.448
Camshaft Position Sensor Bolt 3.3/3.8L1410
Camshaft Position Sensor Bolt 4.0L129
Knock Sensor 3.3/3.8L2015
Knock Sensor 4.0L2015
Ignition Coil Bolt 4.0L871
Ignition Coil Capacitor Bolt 4.0L2820.5
Ignition Coil Nuts 3.3/3.8L12106
Spark Plug 3.3/3.8L17.513
Spark Plug 4.0L2720
Negative Battery Cable Nut545

CABLE - SPARK PLUG 3.3, 3.8L

WARNINGAlways turn the engine off and disconnect the battery prior to servicing the spark plug cables. Do not attempt to remove a spark plug cable while the motor is running. Failure to follow these directions may result in serious or fatal injury.

Disconnect and isolate negative battery cable at battery.

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.

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.

Install negative battery cable to battery.

Scheme 8

Scheme 8: CAPACITOR - IGNITION COIL
Scheme 8: CAPACITOR - IGNITION COIL

The ignition capacitor is located on the drivers side of the engine.

  1. Disconnect and isolate the negative battery cable at battery.
  2. Remove electrical connector (3).
  3. Remove mounting bolt (1) and ignition capacitor (2).

CAPACITOR - IGNITION COIL

  1. Install ignition coil capacitor (2) and bolt (1).
  2. Tighten bolt to 28 N.m (20.5 ft. lbs.).
  3. Connect electrical connector (3).
  4. Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 9

Scheme 9: COIL - IGNITION - 3.3/3.8L
Scheme 9: COIL - IGNITION - 3.3/3.8L
  1. Disconnect and isolate the negative battery cable at battery.
  2. Remove 2 bolts from the Power steering reservoir to intake manifold.
  3. Loosen the lower nut for the power steering reservoir from stud on ignition coil bracket.
  4. Reposition the power steering reservoir.
  5. Remove the ignition cables from the ignition coil.
  6. Disconnect the electrical connector from the ignition coil.
  7. Remove 2 nuts from the ignition coil studs.
  8. Remove ignition coil from engine.

Scheme 10

Scheme 10: COIL - IGNITION - 4.0L
Scheme 10: COIL - IGNITION - 4.0L
  1. Disconnect and isolate the negative battery cable at battery.
  2. Remove intake manifold. Refer to «REMOVAL»(/chrysler/town-country/v-2007-2010/remont/mechanical/#33l-engine-38l-engine-service-information) - 3.3L/3.8L. Refer to «REMOVAL»(/chrysler/town-country/v-2007-2010/remont/mechanical/#40l-engine-service-information) - 4.0L. NOTE: Prior to removing coil, spray compressed air around coil top to make sure no dirt drops into the spark plug tube.
  3. Disconnect electrical connector (1) from ignition coils (3).
  4. Remove mounting bolt (2).
  5. Remove the ignition coil assembly (3) by turning the assembly 1/2 turn and pulling straight up in a steady motion.

COIL - IGNITION - 3.3/3.8L

  1. Install coil over studs on bracket.
  2. Install 2 nuts to the ignition coil studs and tighten nuts.
  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.
  6. Install 2 bolts to the Power steering reservoir to intake manifold.
  7. Tighten the lower nut to stud on ignition coil bracket.
  8. Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

COIL - IGNITION - 4.0L

  1. Install ignition coil (3) and bolt (2).
  2. Tighten bolt to 8 N.m (71 in. lbs.).
  3. Connect the electrical connector (1) to ignition coil.
  4. Install intake manifold. Refer to «INSTALLATION»(/chrysler/town-country/v-2007-2010/remont/mechanical/#33l-engine-38l-engine-service-information) - 3.3L/3.8L. Refer to «INSTALLATION»(/chrysler/town-country/v-2007-2010/remont/mechanical/#40l-engine-service-information) - 4.0L.
  5. Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

PLUG - SPARK 3.3/3.8L

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 circuit 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 compressed 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.

PLUG - SPARK 4.0L

  1. Disconnect and isolate the negative battery cable.
  2. Remove engine cover.
  3. Remove the intake manifold. Refer to «REMOVAL»(/chrysler/town-country/v-2007-2010/remont/mechanical/#33l-engine-38l-engine-service-information) - 3.3L/3.8L. Refer to «REMOVAL»(/chrysler/town-country/v-2007-2010/remont/mechanical/#40l-engine-service-information) - 4.0L. NOTE: Prior to removing coil, spray compressed air around coil top to make sure no debris drops into the spark plug tube.
  4. Disconnect electrical connectors (1).
  5. Remove mounting bolt (2).
  6. Remove the ignition coil assembly (3) by turning the assembly 1/2 turn and pulling straight up in a steady motion. NOTE: Prior to loosening the spark plug, use compressed air to blow out any debris that might be in the spark plug tube.
  7. Remove the spark plug using a quality socket with a foam insert.

Note. When replacing spark plugs and ignition cables, route cables correctly and secure in appropriate retainers. Failure to route ignition cables properly can cause the radio to reproduce noise, cross ignition of the spark plugs or short circuit the cables to ground.

CAUTIONDo not over apply anti-seize compound. Only use enough to lightly coat threads on the spark plug.
  1. Apply a small amount of anti-seize to threads of each spark plug.
  2. Check and adjust spark plug gap, see «SPECIFICATIONS»(/chrysler/town-country/v-2007-2010/remont/ignition-system/#ignition-control-service-information) . CAUTION: Start each spark plug by hand to avoid cross threading and plug damage, use a quality socket with a rubber insert and start each spark plug into the cylinder head by hand.
  3. Install spark plug and tighten to 17.5 N.m (13 ft. lbs.).
  4. Install ignition cables over spark plugs. An audible click noise can be heard and felt when the ignition cable is properly attached to spark plug.
CAUTIONStart each spark plug by hand to avoid cross threading and plug damage, use a quality socket with a rubber insert and start each spark plug into the cylinder head by hand.
  1. Tighten spark plugs to 27 N.m (20 ft. lbs.).
  2. Install ignition coil (3) and bolt (2).
  3. Tighten bolt to 8 N.m (71 in. lbs.).
  4. Connect electrical connector (1) to ignition coil (3).
  5. Install intake manifold. Refer to «INSTALLATION»(/chrysler/town-country/v-2007-2010/remont/mechanical/#33l-engine-38l-engine-service-information) - 3.3L/3.8L. Refer to «INSTALLATION»(/chrysler/town-country/v-2007-2010/remont/mechanical/#40l-engine-service-information) - 4.0L.
  6. Install engine cover.
  7. Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 11

Scheme 11: OPERATION
Scheme 11: OPERATION

Depiction of good camshaft and crankshaft square wave signals for 6 cylinder engines.

Scheme 12

Scheme 12: REMOVAL - 2.8L DIESEL
Scheme 12: REMOVAL - 2.8L DIESEL
  1. Disconnect and isolate the negative battery cable. The Camshaft Position Sensor (CMP) (3) is located at the front/top of the cylinder head.
  2. Remove electrical connector from CMP sensor (3).
  3. Clean area at base of sensor.
  4. Remove sensor mounting bolt (1) and washer (2).
  5. Pull sensor (3) straight up for removal.

Scheme 13

Scheme 13: SENSOR - CAMSHAFT POSITION 3.3/3.8L
Scheme 13: SENSOR - CAMSHAFT POSITION 3.3/3.8L
  1. Disconnect and isolate the negative battery cable at battery.
  2. Remove the air box cover and inlet tube.
  3. Disconnect camshaft position sensor electrical connector from the wiring harness connector.
  4. Remove sensor bolt.
  5. Rotate sensor away from block.
  6. Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal.

Scheme 14

Scheme 14: SENSOR-CAMSHAFT POSITION - 4.0L
Scheme 14: SENSOR-CAMSHAFT POSITION - 4.0L
  1. Disconnect and isolate the negative battery cable at battery.
  2. Remove generator mounting bolts (2), (3) and position the generator (1) aside in order to gain access to the camshaft position (CMP) sensor, refer to «REMOVAL»(/chrysler/town-country/v-2007-2010/remont/charging-system/#charging-system) .
  3. Disconnect electrical connector from CMP sensor.
  4. Remove bolt and CMP.

INSTALLATION - 2.8L DIESEL

  1. Position CMP sensor (3) into mounting hole.
  2. Install sensor mounting bolt (1) and washer (2). Tighten bolt to 11 Nm ( 8 ft. lbs.).
  3. Connect electrical connector to CMP sensor (3).
  4. Reconnect the negative battery cable.

SENSOR - CAMSHAFT POSITION 2.8L DIESEL

  1. Lubricate O-ring and install sensor in cylinder head cover. Torque retaining bolt to 5.4 N.m (48 in. lbs.).
  2. Connect camshaft position sensor electrical connector.
  3. Install engine cover. Refer to «INSTALLATION»(/chrysler/town-country/v-2007-2010/remont/mechanical/#33l-engine-38l-engine-service-information) - 3.3L/3.8L. Refer to «INSTALLATION»(/chrysler/town-country/v-2007-2010/remont/mechanical/#40l-engine-service-information__installation) - 4.0L.
  4. Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 15

Scheme 15: SENSOR - CAMSHAFT POSITION 3.3/3.8L
Scheme 15: SENSOR - CAMSHAFT POSITION 3.3/3.8L
1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER

If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor.

  1. Apply a couple drops of clean engine oil to the O-ring prior to installation.
  2. Install sensor in the chain case cover and rotate into position.
  3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N.m (125 in. lbs.) torque.
  4. Connect camshaft position sensor electrical connector to harness connector.
  5. Install the air box cover and inlet hose.
  6. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

SENSOR-CAMSHAFT POSITION - 4.0L

  1. Install camshaft position (CMP) sensor and bolt. Tighten bolt to 12 N.m (9 ft. lbs.)
  2. Install electrical connector to CMP sensor.
  3. Install the generator (1) and mounting bolts (2), (3), refer to «INSTALLATION»(/chrysler/town-country/v-2007-2010/remont/charging-system/#charging-system) .
  4. Connect the negative battery cable and tighten the nut to 5 N.m (45 in. lbs.).

Scheme 16

Scheme 16: SENSOR - KNOCK - 3.3/3.8L
Scheme 16: SENSOR - KNOCK - 3.3/3.8L
  1. Disconnect and isolate the negative battery cable at battery.
  2. Remove knock sensor cover (4).
  3. Disconnect electrical connector (1) from knock sensor (2).
  4. Remove bolt (3) and knock sensor (2) from engine.

Scheme 17

Scheme 17: SENSOR - KNOCK - 4.0L
Scheme 17: SENSOR - KNOCK - 4.0L
  1. Disconnect and isolate the negative battery cable at battery.
  2. Remove engine cover.
  3. Remove upper intake manifold. Refer to «REMOVAL»(/chrysler/town-country/v-2007-2010/remont/mechanical/#33l-engine-38l-engine-service-information) - 3.3L/3.8L. Refer to «REMOVAL»(/chrysler/town-country/v-2007-2010/remont/mechanical/#40l-engine-service-information) - 4.0L.
  4. Disconnect electrical connector.
  5. Remove knock sensor.

SENSOR - KNOCK - 3.3/3.8L

CAUTIONTorque the knock sensor to correct specification. Over or under tightening effects knock sensor performance, possibly causing improper spark control and damage to the sensor.
  1. Install knock sensor (2) and bolt (3) to engine and tighten to 20 N.m (15 ft. lbs.).
  2. Connect electrical connector (1) to knock sensor (2).
  3. Install knock sensor cover (4).
  4. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

SENSOR - KNOCK - 4.0L

CAUTIONTorque the knock sensor to correct specification. Over or under tightening effects knock sensor performance, possibly causing improper spark control and damage to the sensor.
  1. Install knock sensor and bolt. Tighten bolt to 20 N.m (15 ft. lbs.).
  2. Route knock sensor wire in the proper location.
  3. Install upper intake manifold. Refer to «INSTALLATION»(/chrysler/town-country/v-2007-2010/remont/mechanical/#33l-engine-38l-engine-service-information) - 3.3L/3.8L. Refer to «INSTALLATION»(/chrysler/town-country/v-2007-2010/remont/mechanical/#40l-engine-service-information) - 4.0L.
  4. Connect electrical connector.
  5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 18

Scheme 18: GLOW PLUG
Scheme 18: GLOW PLUG
CAUTIONThe glow plugs operate on a 4.4-volt system. The glow plugs DO NOT tolerate any over voltage. Full battery voltage will destroy the glow plug immediately. DO NOT test the glow plugs with a 12V source as damage will occur to the glow plug.
CAUTIONNever bend, bump or knock the fast metallic glow plugs. Fast metallic glow plugs must not be handled loose in a container. Store, handle, and transport them only in original boxes. If there is any doubt about the proper condition of a glow plug, do not reuse it. Do not clean the glow plugs with abrasive or aggressive media. Avoid dipping the glow plug into fluids. Read Diagnostic Trouble Codes (DTCs). If a glow plug problem is indicated, do not start the engine.
CAUTIONDisregarding these instructions may cause severe engine damage.

Glow plugs are used to help start a cold or cool engine. 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.

Scheme 19

Scheme 19: GLOW PLUG
Scheme 19: GLOW PLUG
CAUTIONThe glow plugs operate on a 4.4-volt system. DO NOT test the glow plugs with a 12 V source as damage will occur to the glow plug(s).

The Engine Control Module (ECM) monitors various engine sensors. When the ignition key is turned to the ON position, the ECM sends a signal to the glow plug module (relay) to turn on, and cycle, the glow plugs for a pre-determined amount of time, plus illuminate the glow plug light in the instrument panel. Once activated, the element inside of the core of the glow plug begins to glow. Each glow plug draws approximately 8 amps, for a total system amperage of 32 amps at 22° C (72° F) ambient temperature. If there is a fault with the glow plug system, the ECM will store a fault code.

GLOW PLUG SYSTEM

CAUTIONDO NOT attempt to start the engine until the glow plug system tests correctly.
  1. Measure the electrical resistance of each glow plug while it is still installed in the cylinder head. Resistance should be less than 0.8 & ohm between the electrical connector point on the glow plug and the cylinder head. The ground contact on the DVOM must be as close as possible to the point where the glow plug contacts the cylinder head to avoid erratic resistance measurements.
  2. If the resistance is out of tolerance, remove the glow plug from the cylinder head and check the resistance again.
  3. Use the actuator test function of the scan tool to test the glow plug module and glow plug lamp. The glow plug module's on-board diagnostic tests will automatically check the electrical condition of the entire glow plug system.
  4. After the scan tool glow plug actuator test function is complete, if MIL is OFF and no glow plug DTCs are present, testing is complete and the engine can be started.
  5. If MIL is still ON, check the harness connectors of glow plugs, repair any loose or damaged connections, and run the glow plug actuator test again.
  6. If MIL is still ON and glow plug DTCs are present, refer to appropriate Engine Electrical Diagnostics - Diesel article, and follow the diagnostic test(s) related to the active or stored DTCs.

Scheme 20

Scheme 20: REMOVAL
Scheme 20: REMOVAL

The four glow plugs (1) are attached to cylinder head below fuel rail.

Scheme 21

Scheme 21
Scheme 21
  1. Disconnect negative battery cable.
  2. Remove fuel rail and high-pressure fuel lines.
  3. Disconnect glow plug wiring harness (2) at all four glow plugs (1).
  4. Use a socket to loosen glow plug(s) (1), (2), (3) or (4). After loosening, attach a flexible tool such as a rubber hose to remove glow plug from cylinder head.
CAUTIONAfter plug removal, do not bend, knock, or drop the glow plugs while handling (any mechanical impact may damage the glow plug).

INSTALLATION

  1. Apply a small amount of clean diesel oil or motor oil to glow plug threads.
  2. Attach a flexible tool such as a rubber hose to install glow plug into cylinder head. Tighten each plug to 14 N.m (10 ft. lbs.) (124 in. lbs.) torque.
  3. Connect glow plug wiring harness (2) to all four glow plugs (1).
  4. Install fuel rail and high-pressure fuel lines.
  5. Connect negative battery cable.

Scheme 22

Scheme 22: REMOVAL
Scheme 22: REMOVAL
  1. Disconnect negative battery cable.
  2. Carefully pull out mounting pin (2).
  3. Disconnect electrical connector (4) from relay (3).
  1. Connect electrical connector (4) to relay.
  2. Push mounting pin (2) through relay (3).
  3. Connect negative battery cable.

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