Ignition System - Service Information: Other Dodge Challenger III рестайлинг

3.6L

The firing order for the 3.6L V-6 is 1-2-3-4-5-6.

Scheme 4

5.7L / 6.4L

The firing order for the 5.7L and 6.4L V-8 is 1-8-4-3-6-5-7-2.

Scheme 5

SPARK PLUGS

IGNITION COIL RESISTANCE

1. Install the ignition coil capacitor (2) and bolt (3). Tighten the bolt to 10 N.m (89 in. lbs.).
2. Connect the electrical connector (1).
3. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

1. Position the ignition capacitor (2) at the left rear corner of intake manifold (3).
2. Install the retaining bolt.
3. Install the electrical connector (1).
4. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

1. Disconnect and isolate the negative battery cable (1).
2. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).
3. If removing the ignition coils from cylinders 1, 3 or 5 on the right side of the engine, first remove the air inlet hose (5). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-489304-S24608231252012072600000) or «BODY, AIR CLEANER, REMOVAL, 5.7L»(ref-489305-S07222356612012072600000) or «BODY, AIR CLEANER, REMOVAL»(ref-489306-S09205338922012072600000) .
4. If removing the ignition coils from cylinders 2, 4 or 6 on the left side of the engine, first remove the air inlet hose, upper intake manifold (2) and insulator. Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-489304-S37202509642012072600000) or «MANIFOLD, INTAKE, REMOVAL, 5.7L»(ref-489305-S17410474082012072600000) or «MANIFOLD, INTAKE, REMOVAL»(ref-489306-S15645745872012072600000) . NOTE: The left side ignition coils are shown in illustration, the right side ignition coils are similar.
5. Unlock and disconnect the electrical connector (1) from the ignition coil.
6. Remove the ignition coil retaining bolt (3).
7. Pull the ignition coil (2) from cylinder head cover opening with a slight twisting action.

Scheme 11

Scheme 12

1. Disconnect and isolate the negative battery cable.
2. Disconnect the electrical connector (1) from the coil.
3. Remove the two coil retaining bolts (3).
4. Using a slight rocking motion, carefully lift coil (1) from the cylinder head opening.

Scheme 13

Scheme 14

Scheme 15

1. Using compressed air, blow out any dirt or contaminants from around the top of spark plug.
2. Check the condition of the ignition coil rubber boot (1). Inspect the opening of the boot (2) for any debris, tears or rips. Carefully remove any debris with a lint free cloth. CAUTION: Do not apply a silicone based grease such as Mopar® Dielectric Grease to the ignition coil rubber boot. The silicone based grease will absorb into the boot causing it to stick and tear.
3. Place a small, 360° bead of Fluostar 2LF lubricant (1) along the inside opening of the coil boot approximately 1 to 2 mm from the chamfer edge but not on the chamfered surface. NOTE: The LH ignition coils are shown in illustration, the RH ignition coils are similar.
4. Position the ignition coil (2) into the cylinder head cover opening. Using a twisting action, push the ignition coil onto the spark plug.
5. Install the ignition coil mounting bolt (3) and tighten to 8 N.m (71 in.lbs).
6. Connect and lock the electrical connector (1) to the ignition coil (2).
7. If removed, install the insulator, upper intake manifold (1) and air inlet hose. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-489304-S37350973732012072600000) or «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-489305-S37168400762012072600000) or «MANIFOLD, INTAKE, INSTALLATION»(ref-489306-S33067186472012072600000) .
8. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

1. Before installing coil(s), apply dielectric grease to the inside of spark plug boots (1).
2. Position the ignition coil into cylinder head and push both spark plug boots onto each spark plug.
3. Install the two coil mounting bolts (3) and tighten to 12 N.m (106 in. lbs.).
4. Connect the electrical connector (1) to the coil and lock connector.
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 16

The two Camshaft Position (CMP) sensors are located at the rear of the cylinder head covers. The sensors are bolted to the cylinder head and utilize a radial lip seal where they protrude through the covers. The attaching bolt (2) has an O-ring seal and is captured in the sensor.

Scheme 17

The Camshaft Position Sensors (CMP) sensors (1) are dual read, single element hall effect sensors mounted between the magnetic encoded timing wheels (2). The magnetic timing wheels are used because of their small diameter allowing for a compact cylinder head design.

Scheme 18

The Camshaft Position Sensor (CMP) (1) is located in the timing cover near the thermostat housing.

Scheme 19

The 3.6 liter engine uses a Dual Over Head Camshaft (DOHC) configuration. The camshafts are a nodular cast iron design and have two pressed on magnetic timing wheels (1) that are magnetically encoded.

The Camshaft Position Sensors (CMP) are mounted between the timing wheels (1).

5.7L/6.4L

The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor.

The tonewheel is located at the front of the camshaft. As the tonewheel rotates, notches pass through the sync signal generator.

When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts.

The Camshaft Position (CMP) sensors are located at the rear of the cylinder head covers and are bolted to the cylinder head.

Scheme 20

1. Disconnect and isolate the negative battery cable.
2. If removing the left CMP sensor, first remove the air inlet hose and upper intake manifold (2). Refer to «MANIFOLD, INTAKE, REMOVAL»(ref-489304-S37202509642012072600000) or «MANIFOLD, INTAKE, REMOVAL, 5.7L»(ref-489305-S17410474082012072600000) or «MANIFOLD, INTAKE, REMOVAL»(ref-489306-S15645745872012072600000) . NOTE: The right CMP sensor is shown in illustration, the left CMP sensor is similar. If removing both right and left CMP sensors, mark the sensors so they can be installed in their original locations.
3. Disconnect the electrical connector (1) from the CMP sensor.
4. Loosen the sensor mounting bolt (2).
5. Pull the sensor and mounting bolt from the cylinder head cover.
6. The O-ring seal (1) can be reused if not damaged.

Scheme 21

1. Disconnect and isolate the negative battery cable.
2. Disconnect the electrical connector (4) at the Camshaft Position (CMP) sensor (1).
3. Remove the CMP sensor mounting bolt (3).
4. Using a slight rotating motion, carefully remove the CMP sensor from the timing cover (2).
5. Check the condition of the sensor O-ring.

Scheme 22

Scheme 23

Scheme 24

1. Clean out the camshaft position (CMP) sensor mounting bolt hole (2) in cylinder head.
2. The CMP sensor seal (1) can be reused if not damaged.
3. If required, install a new CMP sensor seal (2) in the cylinder head cover: Lubricate the CMP sensor seal inner and outer diameters with clean engine oil. Place the CMP sensor seal (2) on the Cam Sensor/Spark Plug Tube Seal Installer (special tool #10256, Installer, Cam Installer, Cam Sensor/ Spark Plug Tube Seal) (1). Push the seal into the cylinder head cover until the base of the seal is seated. Remove the tool. NOTE: A properly installed CMP sensor seal (1) will have a 1.5 - 2.0 mm (0.06 - 0.08 in.) gap (2) between the cylinder head cover and the seal upper flange.
4. The sensor mounting bolt O-ring (1) can be reused if not damaged.
5. Apply a small amount of engine oil to the sensor mounting bolt O-ring (1). NOTE: The right CMP sensor is shown in illustration, the left CMP sensor is similar. If both right and left CMP sensors where removed, install them into their original locations.
6. Install the CMP sensor to the cylinder head. Tighten the mounting bolt (2) to 9 N.m (80 in. lbs.).
7. Connect the electrical connector (1) to the sensor.
8. If required, install the upper intake manifold (1) and air inlet hose. Refer to «MANIFOLD, INTAKE, INSTALLATION»(ref-489304-S37350973732012072600000) or «MANIFOLD, INTAKE, INSTALLATION, 5.7L»(ref-489305-S37168400762012072600000) or «MANIFOLD, INTAKE, INSTALLATION»(ref-489306-S33067186472012072600000) .
9. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Note. The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

1. Using a slight rotating motion, carefully install the CMP sensor (1) into the timing cover (2). CAUTION: Before tightening the sensor mounting bolt, be sure the sensor is completely flush to the timing cover. If the sensor is not flush, damage to the sensor mounting tang may result.
2. Install the CMP mounting bolt (3) and tighten to 12 N.m (9 ft. lbs.).
3. Connect the electrical connector (4) to the CMP sensor.
4. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 25

Note. The forward knock sensor (1) is known to the Powertrain Control Module (PCM) as Knock Sensor 1. The rear knock sensor (3) is known to the PCM as Knock Sensor 2.

The 3.6L engine uses two knock sensors (1, 3) and are bolted to the cylinder block under the intake manifold.

Scheme 26

The 5.7L and 6.4L engines use two knock sensors (1) and are bolted to each side of the cylinder block (outside) under each exhaust manifold (3).

Note. The forward sensor (1) is known to the powertrain control module (PCM) as knock sensor 1. The rear sensor (3) is known to the PCM as knock sensor 2.

1. Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-489307-S24512055572012072600000) .
2. Disconnect and isolate the negative battery cable.
3. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-489282-S15090009642012072600000) .
4. Remove the air cleaner housing assembly, upper and lower intake manifolds and the oil filter housing. Refer to «HOUSING, OIL FILTER, REMOVAL»(ref-489304-S23022887372012072600000) .
5. Remove the knock sensor electrical connector (4). NOTE: There may be a foam strip on the bolt threads. This foam is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
6. Remove the retaining bolt (2) and knock sensor 1 (1) or knock sensor 2 (3).

Scheme 27

Two knock sensors are used. Each sensor is bolted to the outside of cylinder block below the exhaust manifold.

1. Disconnect and isolate the negative battery cable.
2. Raise and support the vehicle.
3. Remove the heat shield (1) from knock sensor (shield snaps onto sensor).
4. Disconnect the knock sensor electrical connector (5). NOTE: Note the foam strip on the knock sensor retaining bolt threads. This foam is only used to retain the bolts to the knock sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
5. Remove the knock sensor retaining bolt (2).
6. Remove the knock sensor from the cylinder block.

Note. The forward sensor (1) is known to the powertrain control module (PCM) as knock sensor 1. The rear sensor (3) is known to the PCM as knock sensor 2.

1. Thoroughly clean the knock sensor mounting holes. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque specification for the knock sensor bolt is less than the typical 8 mm bolt. NOTE: There may be a foam strip on the bolt threads. This foam is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
2. Install knock sensor 1 (1) or knock sensor 2 (3) and retaining bolt (2). Tighten the retaining bolt to 22 N.m (16 ft. lbs.).
3. Connect the electrical connector (4).
4. Install the oil filter housing, upper and lower intake manifolds and air cleaner housing assembly. Refer to «HOUSING, OIL FILTER, INSTALLATION»(ref-489304-S38739146322012072600000) .
5. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to «LUBRICATION»(ref-489304-S25687069542012072600000) or «LUBRICATION»(ref-489305-S28795284032012072600000) or «LUBRICATION»(ref-489306-S12470295832012072600000) .
6. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
7. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-489282-S15090009642012072600000) .
8. Operate the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to «STANDARD PROCEDURE»(ref-489282-S15090009642012072600000) .

1. Position the knock sensor (1) onto cylinder block. NOTE: The foam strip used on bolt threads is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
2. Install the retaining bolt and tighten (2) to 20 N.m (15 ft. lbs.).
3. Connect the electrical connector (5) to the knock sensor.
4. Snap the heat shield (1) onto the knock sensor.
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Scheme 28

The 3.6L engine is equipped with Variable Valve Timing (VVT). This system adjusts the timing of all four camshafts independently using solenoids and oil control valves to direct oil pressure into the camshaft phaser assemblies. The camshaft phaser assembly advances and/or retards camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The four VVT solenoids are located on the front of the cylinder head covers. The pintle should move freely within the solenoid body. Do not attempt to disassemble the solenoids, they are not serviceable. The solenoids are identical but should be installed in the same location as removed.

Scheme 29

Camshaft phaser position is adjusted using regulated oil pressure through an Oil Control Valve (OCV) (3). To begin Phaser movement, the Powertrain Control Module (PCM) applies a pulse-width modulated voltage signal to the VVT solenoid (1) to extend or retract the solenoid pintle (4). The pintle pushes against an internal spool valve (2) within the OCV moving the valve forwards and backwards to direct oil flow. The position of the spool inside the OCV determines which ports and chambers inside the phaser are being fed, either to advance the timing of the phaser sprocket relative to the camshaft, retard it, or hold a desired position. Refer to ASSEMBLY, VARIABLE VALVE TIMING, PHASER / OIL CONTROL VALVE, OPERATION .

The Camshaft Position (CMP) sensor monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM.

Scheme 30

Scheme 31

Scheme 32

1. Disconnect and isolate the negative battery cable (1).
2. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).
3. Disconnect the electrical connector (1) from the Inlet Air Temperature (IAT) sensor.
4. Loosen the clamp (2) at the throttle body.
5. Loosen the clamp (3) at the air cleaner housing.
6. Lift the air inlet hose assembly retaining grommet off the ball stud (4).
7. Remove the air inlet hose assembly (5).
8. Disconnect the fresh air makeup hose (1) from the air cleaner housing.
9. Remove the air cleaner housing retaining bolt (2).
10. Remove the air cleaner housing (3). NOTE: Mark the variable valve timing solenoid connectors (1) with a paint pen or equivalent so that they may be reinstalled in their original locations.
11. Mark the intake variable valve timing solenoid (4) and the exhaust variable valve timing solenoid (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.
12. Disconnect the electrical connector (1) from the variable valve timing solenoid.
13. Remove the variable valve timing solenoid mounting bolts (3).
14. Pull the variable valve timing solenoid from the cylinder head cover.
15. The seal (1) can be reused if not damaged.

Scheme 33

1. Disconnect and isolate the negative battery cable. NOTE: Mark the variable valve timing solenoid connectors (1) with a paint pen or equivalent so that they may be reinstalled in their original locations.
2. Mark the intake variable valve timing solenoid (2) and the exhaust variable valve timing solenoid (4) with a paint pen or equivalent so that they may be reinstalled in their original locations.
3. Disconnect the electrical connector (1) from the variable valve timing solenoid.
4. Remove the variable valve timing solenoid mounting bolts (3).
5. Pull the variable valve timing solenoid from the cylinder head cover.
6. The seal (1) can be reused if not damaged.

LEFT

1. Install the variable valve timing solenoid seals (1). The seals can be reused if not damaged.
2. Refer to the markings made at disassembly and install the intake variable valve timing solenoid (4) and the exhaust variable valve timing solenoid (2) in their original locations.
3. Install the variable valve timing solenoid mounting bolts (3) and tighten to 4 N.m (35 in. lbs.).
4. Connect the electrical connector (1) to the variable valve timing solenoid.
5. Position the air cleaner housing (3) into the vehicle.
6. Install the air cleaner housing retaining bolt (2) and tighten to 12 N.m (9 ft. lbs.).
7. Connect the fresh air makeup hose (1) to the air cleaner housing.
8. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
9. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
10. Tighten the clamp at the air cleaner housing (3) to 5 N.m (44 in. lbs.).
11. Tighten the clamp (2) at the throttle body to 5 N.m (44 in. lbs.).
12. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).
13. Position the engine cover (1) and secure the retaining grommets onto the ball studs.
14. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Note. The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

RIGHT

1. Install the variable valve timing solenoid seals (1). The seals can be reused if not damaged.
2. Refer to the markings made during disassembly and install the intake variable valve timing solenoid (2) and the exhaust variable valve timing solenoid (4) in their original locations.
3. Install the variable valve timing solenoid mounting bolts (3) and tighten to 4 N.m (35 in. lbs.).
4. Connect the electrical connector (1) to the variable valve timing solenoid.
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

Note. The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

Note. The left side ignition coils are shown in illustration, the right side ignition coils are similar.

Scheme 34

1. Remove the ignition coil (2). Refer to «COIL, IGNITION, REMOVAL»(ref-489335-S14494677252012072600000) . CAUTION: The spark plug tubes (1) are a thin wall design. Avoid damaging the spark plug tubes. Damage to the spark plug tube can result in oil leaks.
2. Prior to removing the spark plug, spray compressed air into the cylinder head opening. This will help prevent foreign material from entering combustion chamber.
3. Remove the spark plug from the cylinder head using a quality thin wall socket with a rubber or foam insert.
4. Inspect the spark plug condition.

1. Disconnect and isolate the negative battery cable.
2. Disconnect the coil electrical connector (1).
3. Remove the coil mounting bolts (3).
4. Carefully lift coil from the cylinder head opening with a slight rocking motion. CAUTION: Prior to removing the spark plugs, use compressed air to remove any accumulated dirt and debris. If dirt and debris enter the engine, this may cause internal engine damage.
5. Remove the spark plug(s) from the cylinder head using a quality deep well socket with a rubber or foam insert.

Scheme 35

1. Check and adjust the spark plug gap with a gap gauging tool (1). Refer to «SPECIFICATIONS»(ref-489335-S24342911292012072600000) . CAUTION: 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 electrodes can be damaged. CAUTION: The spark plug tubes (1) are a thin wall design. Avoid damaging the spark plug tubes. Damage to the spark plug tube can result in oil leaks.
2. Start the spark plug into the cylinder head by hand to avoid cross threading. CAUTION: Spark plug torque is critical and must not exceed the specified value. Overtightening stretches the spark plug shell reducing its heat transfer capability resulting in possible catastrophic engine failure.
3. Tighten the spark plugs to 17.5 N.m (13 ft. lbs.). NOTE: The left side ignition coils are shown in illustration, the right side ignition coils are similar.
4. Install the ignition coil (2). Refer to «COIL, IGNITION, INSTALLATION»(ref-489335-S04814169602012072600000) .

1. To avoid cross threading, start the spark plug(s) into the cylinder head by hand.
2. Tighten the spark plugs as follows: 5.7L - 25 - 30 N.m (18.5 - 22 ft. lbs.) 6.4L - 10 - 20 N.m (7.5 - 15 ft. lbs.)
3. Apply dielectric grease to the inside of spark plug boots (1).
4. Position the ignition coil into the cylinder head and push both spark plug boots onto each spark plug.
5. Install the ignition coil retaining bolts (3) and tighten to 12 N.m (9 ft. lbs.).
6. Connect the ignition coil electrical connector (1).
7. Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).