Ignition Control System: Removal & Installation Dodge Caravan IV

REMOVAL - 2.4L

The camshaft position sensor is mounted to the rear of the cylinder head.

Scheme 7

1. Remove the negative battery cable.
2. Disconnect electrical connectors from the camshaft position sensor. (Scheme 7)
3. Remove camshaft position sensor mounting screws. Remove sensor.
4. Loosen screw attaching target magnet to rear of camshaft and remove magnet. (Scheme 8)

Scheme 8

Scheme 9

Scheme 10

1. Disconnect the negative battery cable.
2. Remove the air box cover and inlet tube. (Scheme 9)
3. Disconnect camshaft position sensor electrical connector from the wiring harness connector. (Scheme 10)
4. Remove bolt holding sensor.
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.

INSTALLATION - 2.4L

The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft. (Scheme 11)

Scheme 11

1. Install target magnet in end of camshaft. Tighten mounting screw to 3 N.m (30 in. lbs.) torque. Over torquing could cause cracks in magnet. If magnet cracks replace it.
2. Install camshaft position sensor. Tighten sensor mounting screws to 12.9 N.m (115 in. lbs.) torque.
3. Carefully attach electrical connector to camshaft position sensor.
4. Connect the negative battery cable.

INSTALLATION - 3.3/3.8L

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. (Scheme 12)

Scheme 12

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. (Scheme 9)
6. Connect the negative battery cable.

The electronic ignition coil pack attaches directly to the valve cover.

1. Disconnect the negative battery cable.
2. Disconnect electrical connector from coil pack.
3. Remove coil pack mounting bolts.
4. Remove coil pack and heat shield. see scheme 11

Scheme 13

1. Disconnect the negative battery cable.
2. Remove the throttle and speed control cables from clip.
3. Remove 2 bolts from the Power steering reservoir 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. (Scheme 13)
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.

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.

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. (Scheme 13)
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.

The knock sensor threads into the side of the cylinder block in front of the starter. (Scheme 14)

1. Disconnect electrical connector from knock sensor.
2. Use a crow foot socket to remove the knock sensors.

REMOVAL - 3.8L

The knock sensor threads into the side of the cylinder 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 «DIAGNOSIS & OVERHAUL»(ref-248905) article for more information.
4. Disconnect electrical connector from knock sensor.
5. Use a crow foot socket to remove the knock sensor.

The knock sensor threads into the side of the cylinder block in front of the starter. (Scheme 14)

1. Install knock sensor. Tighten knock sensor to 10 N.m (7 ft. lbs.) torque. Over or under tightening effects knock sensor performance, possibly causing improper spark control.
2. Attach electrical connector to knock sensor.

Scheme 14

INSTALLATION - 3.8L

The knock sensor threads into the side of the cylinder block in the rear.

1. Install knock sensor. Tighten knock sensor to 10 N.m (7 ft. lbs.) torque. Over or under tightening 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 «DIAGNOSIS & OVERHAUL»(ref-248905) for more information.
4. Lower vehicle.
5. Connect the negative cable.

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 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.

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 circuit 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 see scheme 15
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.

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.