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Ignition Control - Service Information: Other Dodge Journey I

Ignition System 17 illustrations ~1880 words

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. Corporation2.4L, 2.7L, 3.5L0.495 to 0.605 ohms5.13K to 6.27K ohms

IGNITION COIL RESISTANCE

SPARK PLUG

EngineSpark PlugElectrode GapThread Size
2.4L* (with PZEV)ZFR5AP0.8 mm (0.031 in.)M14 X 1.25
2.4L (without PZEV)ZFR5F-111.1 mm (0.043 in.)M14 X 1.25
2.7LTE10PMC51.27 mm (0.050 in.)M14 X 1.25
3.5LZFR5LP-13G1.27 mm (0.050 in.)M14 X 1.25
*Partial Zero Emission Vehicle

SPARK PLUG

2.4L

1 - Bolt
2 - Capacitor
3 - Connector
  1. Install ignition coil capacitor (2) and bolt (1), tighten bolt to 10 N.m (88.5 ft. lbs.).
  2. Connect electrical connector (3).
  3. Install engine cover.
  4. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).

2.7L 1st

  1. Install ignition coil capacitor and nut.
  2. Tighten nut to 10 N.m (88.5 in. lbs.).
  3. Attach electrical connector to capacitor.
  4. Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).

2.7L 2nd

  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.).

3.5L

  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 18

Scheme 18: 2.4L
Scheme 18: 2.4L

Note. Prior to removing coil, spray compressed air around coil top to make sure no dirt drops into the spark plug tube.

The electronic ignition coil attaches directly to the valve cover.

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Disconnect and isolate the negative battery cable.
  2. Remove engine cover.
  3. Disconnect electrical connector from ignition coil.
  4. Remove ignition coil mounting bolts.
  5. Twist the ignition coil then pull straight up.

Scheme 21

Scheme 21: 2.7L
Scheme 21: 2.7L

Note. Always remove the ignition coil assembly by turning the assembly 1/2 turn and pulling up in a steady motion.

  1. Disconnect the negative battery cable.
  2. Remove the upper intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353574-S17562254772010011200000) .
  3. Disconnect electrical connector (1) from ignition coil.
  4. Remove mounting bolt (2) from ignition coil. CAUTION: Prior to removing the ignition coils, spray compressed air around the coils and spark plugs. If dirt and debris enter the engine, this may cause internal engine damage.
  5. Remove the ignition coils.

Scheme 22

Scheme 22: 3.5L
Scheme 22: 3.5L

Scheme 23

Scheme 23
Scheme 23
  1. Remove engine cover.
  2. Disconnect and isolate the negative battery cable.
  3. Remove the upper intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353574-S17562254772010011200000) .
  4. Unlock and disconnect electrical connector (2) from ignition coils.
  5. Remove mounting bolts and engine cover studs (1). CAUTION: Prior to removing the ignition coils, spray compressed air around the coils and spark plugs. If dirt and debris enter the engine, this may cause internal engine damage.
  6. Twist, lift and remove ignition coil from engine.
  1. Install ignition coil onto spark plug.
  2. Install ignition coil mounting bolt, tighten to 9 N.m (79.5 in. lbs.).
  3. Connect ignition coil electrical connectors.
  4. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).
  5. Install engine cover.

2.7L

  1. Align ignition coil with top of spark plug.
  2. Twist and push down ignition coil assembly onto spark plug and valve cover. Install mounting bolt (2) and tighten to 7.5 N.m (65 in. lbs.).
  3. Connect electrical connector (1) to ignition coil.
  4. Install upper intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353574-S32430514252010011200000) .
  5. Connect negative battery cable.

Scheme 24

Scheme 24
Scheme 24
  1. Install ignition coil (1).
  2. Install engine cover studs (1) in the two outside ignition coils on the front of the engine. Install bolts on the other ignition coils.
  3. Tighten studs and bolts to 8 N.m (71 in. lbs.).
  4. Connect electrical connector and lock (2).
  5. Install intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353574-S32430514252010011200000) .
  6. Connect negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  7. Install engine cover.

Scheme 25

Scheme 25: DESCRIPTION
Scheme 25: DESCRIPTION

The glow plug control module is mounted to the fuel filter/water separator bracket, and is controlled by the engine control module.

2.4L FRONT

CAUTIONInstall camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all.
  1. Lubricate sensor O-ring.
  2. Install CMP sensor and mounting bolt, tighten to 9 N.m (79.5 in. lbs.).
  3. Connect electrical connector to camshaft position sensor.
  4. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).

2.4L REAR

CAUTIONInstall camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all.
  1. Lubricate sensor O-ring.
  2. Install CMP sensor and mounting bolt, tighten to 9 N.m (79.5 in. lbs.).
  3. Connect electrical connector to camshaft position sensor.
  4. Install heat shield onto mounting stud.
  5. Install heat shield retaining nut and tighten.
  6. Connect the electrical connector.
  7. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).
CAUTIONInstall camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all.

Note. If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor.

  1. Push the CMP sensor into the chain case cover with a twisting motion until fully seated.
  2. While holding the sensor in this position, install and tighten the retaining bolt to 12 N.m (106 in. lbs.).
  3. Connect and lock the electrical connector to the CMP sensor.
  4. 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 anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to «DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure»(ref-353603-S03528494482010011200000)
CAUTIONInstall camshaft position (CMP) sensor utilizing twisting motion. Make sure CMP sensor is fully seated. Do not drive CMP sensor into the bore with mounting screw. This may cause CMP sensor to be incorrectly seated causing a faulty signal or no signal at all.

Note. If reinstalling the sensor, check the sensor O-ring for damage and replace if necessary. Lubricate the O-ring with clean engine oil before installing the sensor.

  1. Push the CMP sensor (2) into the timing belt cover with a twisting motion until fully seated.
  2. While holding the sensor (2) in this position, install and tighten the retaining bolt (1) to 12 N.m (106 in. lbs.).
  3. Connect and lock the electrical connector (3) to the CMP sensor (2).
  4. 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 anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to «DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure»(ref-353603-S03528494482010011200000)

Scheme 26

Scheme 26: 2.4L
Scheme 26: 2.4L

The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold.

Scheme 27

Scheme 27
Scheme 27
  1. Disconnect and isolate negative battery cable.
  2. Disconnect electrical connector (3) from knock sensor (2).
  3. Remove bolt (1) and knock sensor (2) from engine block.

Scheme 28

Scheme 28: 2.7L
Scheme 28: 2.7L
1 - Bolts
2 - Coolant Temp Sensor Connector
3 - Radiator Upper Hose
4 - Water Housing Outlet Tube
5 - Heater Hose
6 - Retaining Clip
WARNINGDo not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
  1. Drain cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
  2. Disconnect and isolate the negative battery cable.
  3. Remove lower intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353574-S17562254772010011200000) .
  4. Remove radiator upper hose (3) at water housing outlet tube (4).
  5. Remove heater hose (5) from water housing outlet tube (4) at rear of engine.
  6. Disconnect water housing outlet tube (4) from retaining clip (6) at rear of engine.
  7. Disconnect electrical connector (2) from coolant temperature sensor.
  8. Remove 4 bolts (1) attaching water housing outlet tube (4) to cylinder heads.
  9. Disconnect electrical connector from knock sensor. 1 - Stud 2 - Nut 3 - Knock Sensor
  10. Reposition the water housing outlet tube and remove nut (2) from knock sensor mounting stud (1).
  11. Remove knock sensor (3) from engine block.

Scheme 31

Scheme 31
Scheme 31
  1. Disconnect the negative battery cable.
  2. Remove the upper intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353574-S17562254772010011200000) .
  3. Disconnect the electrical connector.
  4. Remove the knock sensor .
CAUTIONAlways torque knock sensors to the correct torque specification. Over or under tightening effects knock sensor performance. Ensure the electrical connector orientation is at the sic O'clock position to the engine block.
  1. Install knock sensor (2) and bolt (1) to engine block. Tighten bolt to 22 N.m (195 in. lbs.).
  2. Connect electrical connector (3) to knock sensor (2).
  3. Connect negative battery cable, tighten nut to 4.5 N.m (40 in. lbs.).
1 - Stud
2 - Nut
3 - Knock Sensor
CAUTIONOver or under tightening effects knock sensor performance resulting in possible improper spark control.

Scheme 32

Scheme 32
Scheme 32
  1. Install knock sensor (3) and nut (2) onto stud (1).
  2. Tighten knock sensor nut to 15 N.m (11 ft. lbs.).
  3. Attach electrical connector to knock sensor. 1 - Bolts 2 - Coolant Temp Sensor Connector 3 - Radiator Upper Hose 4 - Water Housing Outlet Tube 5 - Heater Hose 6 - Retaining Clip
  4. Position the water housing outlet tube (4) to the cylinder heads and loosely install four bolts (1).
  5. Attach water housing outlet tube (4) to the retaining clip (6) at rear of engine.
  6. Tighten the four bolts (1) to 3 N.m (30 in. lbs.).
  7. Connect electrical connector (2) to the coolant temperature sensor.
  8. Install heater hose (5) to water housing outlet tube (4) at rear of engine.
  9. Install radiator upper hose (3) to water housing outlet tube (4).
  10. Install intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353574-S32430514252010011200000) .
  11. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).
  12. Fill cooling system. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) .
  13. Operate engine until it reaches normal operating temperature. Check cooling system for correct fluid levels.

Scheme 33

Scheme 33: 3.5L
Scheme 33: 3.5L
CAUTIONAlways use the specified torque when installing the knock sensor bolt. Over or under tightening the sensor mounting bolt will affect knock sensor performance, possibly causing improper spark control.
  1. Install knock sensor. Tighten knock sensor to 20 N.m (15 ft. lbs.).
  2. Route the knock sensor wire in the proper location.
  3. Install upper intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353574-S32430514252010011200000) .
  4. Connect the electrical connector.
  5. Connect the negative battery cable.

Note. Prior to removing coil, spray compressed air around coil top to make sure no dirt drops into the spark plug tube.

Scheme 34

Scheme 34
Scheme 34
  1. Disconnect and isolate the negative battery cable.
  2. Remove engine cover.
  3. Disconnect the electrical connectors from ignition coils.
  4. Remove the ignition coil mounting bolt.
  5. Twist the ignition coil then pull straight up. NOTE: Prior to loosening the spark plug, use compressed air to blow out any debris that might be in the spark plug tube.
  6. Remove the spark plug using a quality socket with a rubber or foam insert.
  7. Inspect the spark plug condition.

Note. Always remove the ignition coil assembly by turning the assembly 1/2 turn and pulling straight back in a steady motion.

  1. Disconnect the negative battery cable.
  2. Remove the upper intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353574-S17562254772010011200000) .
  3. Disconnect electrical connector (1) from ignition coil.
  4. Remove mounting bolt (2) from ignition coil. CAUTION: Prior to removing the ignition coils, spray compressed air around the coils and spark plugs. If dirt and debris enter the engine, this may cause internal engine damage.
  5. Remove the ignition coils.
  6. Remove the spark plugs.
  1. Remove engine cover.
  2. Disconnect and isolate the negative battery cable.
  3. Remove the intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-353574-S17562254772010011200000) .
  4. Unlock and disconnect electrical connector (2) from ignition coils.
  5. Remove mounting bolts and engine cover studs (1).
  6. Twist, lift and remove ignition coil from engine. 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.
  7. Remove spark plug using a quality socket with a rubber or foam insert.
CAUTIONHandle the spark plugs with care. Do not drop or force the spark plugs into the wells, damage to the electrodes and/or porcelain body may occur. Always start each spark plug by hand in order to avoid cross-threading the spark plug in the cylinder head. Always tighten spark plugs to the specified torque. Too much or not enough torque will cause damage to the cylinder head and/or spark plug and may lead to poor engine performance.
  1. Install each spark plug to the cylinder head. Tighten spark plugs to 27 N.m (20 ft. lbs.).
  2. Install ignition coil onto spark plug.
  3. Install ignition coil mounting bolt. Tighten to 9 N.m (79.5 in. lbs.).
  4. Connect ignition coil electrical connectors.
  5. Connect negative battery cable, tighten nut to 5 N.m (45 in. lbs.).
  6. Install engine cover.
CAUTIONHandle the spark plugs with care. Do not drop or force the spark plugs into the wells, damage to the electrodes and/or porcelain body may occur. Always start each spark plug by hand in order to avoid cross-threading the spark plug in the cylinder head. Always tighten spark plugs to the specified torque. Too much or not enough torque will cause damage to the cylinder head and/or spark plug and may lead to poor engine performance.
  1. Install each spark plug to the cylinder head. Tighten spark plugs to 17 N.m (13 ft. lbs.).
  2. Align ignition coil with top of spark plug.
  3. Twist and push down ignition coil assembly onto spark plug and valve cover. Install mounting bolt (2) and tighten to 7.5 N.m (65 in. lbs.).
  4. Connect electrical connector (1) to ignition coil.
  5. Install upper intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353574-S32430514252010011200000) .
  6. Connect negative battery cable.
CAUTIONHandle the spark plugs with care. Do not drop or force the spark plugs into the wells, damage to the electrodes and/or porcelain body may occur. Always start each spark plug by hand in order to avoid cross-threading the spark plug in the cylinder head. Always tighten spark plugs to the specified torque. Too much or not enough torque will cause damage to the cylinder head and/or spark plug and may lead to poor engine performance.
  1. To avoid cross threading, start the spark plug into the cylinder head by hand.
  2. Tighten spark plugs to 27 N.m (20 ft. lbs.).
  3. Install ignition coil.
  4. Install engine cover studs (1) in the two outside ignition coils on the front of the engine. Install bolts on the other ignition coils.
  5. Tighten studs and bolts to 8 N.m (71 in. lbs.).
  6. Connect electrical connector and lock (2).
  7. Install intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-353574-S32430514252010011200000) .
  8. Reconnect the negative battery cable.
  9. Install the engine cover.

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