Ignition System - Service Information: Other Jeep Commander I

IGNITION SYSTEM-4.7L

The 4.7L uses separate ignition coils for each cylinder. The one-piece coil bolts directly to the cylinder head. Rubber boots seal the secondary terminal ends of the coils to the top of all 8 spark plugs. A separate electrical connector is used for each coil.

Because of coil design, spark plug cables (secondary cables) are not used. A distributor is not used.

Two knock sensors (one for each cylinder bank) are used to help control spark knock.

The Auto Shutdown (ASD) relay provides battery voltage to each ignition coil.

The ignition system consists of

1. 8 Spark Plugs
2. 8 Separate Ignition Coils
3. 2 Knock Sensors
4. Powertrain Control Module (PCM)
5. Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors

IGNITION SYSTEM-3.7L

The ignition system is controlled by the Powertrain Control Module (PCM) on all engines.

The 3.7L uses separate ignition coils for each cylinder. The one-piece coil bolts directly to the cylinder head. Rubber boots seal the secondary terminal ends of the coils to the top of all 6 spark plugs. A separate electrical connector is used for each coil.

Because of coil design, spark plug cables (secondary cables) and a distributor are not used.

Two knock sensors (one for each cylinder bank) are used to help control spark knock.

The Auto Shutdown (ASD) relay provides battery voltage to each ignition coil.

The ignition system consists of

1. 6 Spark Plugs
2. 6 Separate Ignition Coils
3. 2 Knock Sensors
4. Powertrain Control Module (PCM)
5. Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors

IGNITION SYSTEM-5.7L

The 5.7L is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches to the spark plugs.

Two knock sensors (one for each cylinder bank) are used to help control spark knock.

The ignition system consists of

1. 16 Spark Plugs (2 per cylinder)
2. 8 Separate, Ignition Coils
3. 2 Knock Sensors
4. Powertrain Control Module (PCM)
5. Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors

IGNITION COIL RESISTANCE - 4.7L

IGNITION COIL RESISTANCE - 5.7L

Scheme 22

SPARK PLUGS

SPARK PLUG SPECIFICATION

ENGINE FIRING ORDER - 3.7L

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

Scheme 23

These numbers (2) and (3) can also be found on the top of the intake manifold (1) to the right of the throttle body.

IGNITION TIMING

Ignition timing is not adjustable on any of the available engines.

IGNITION COIL RESISTANCE - 3.7L

IGNITION COIL RESISTANCE

AUTO SHUTDOWN (ASD) RELAY - PCM OUTPUT

The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location.

AUTOMATIC SHUTDOWN (ASD) RELAY SENSE - PCM INPUT

A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply.

This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC).

The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements.

The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off.

The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if

1. The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds.
2. There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values.

AUTOMATIC SHUTDOWN (ASD) RELAY

The ASD relay is located in the engine compartment within the Power Distribution Center (PDC). Refer to label on PDC cover for relay location.

1. Remove PDC cover.
2. Remove relay from PDC.
3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay.
4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay.

The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location.

1. Install relay to PDC.
2. Install cover to PDC.

Scheme 24

The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine.

Scheme 25

The Camshaft Position Sensor (CMP) (3) is bolted to the right-front side of the right cylinder head (2).

SENSOR-CAMSHAFT POSITION-5.7L/6.1L

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 (2). As the tonewheel rotates, notches (3) 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.

Scheme 26

The Camshaft Position Sensor (CMP) sensor on the 3.7L (3) contains a hall effect device referred to as a sync signal generator. A rotating target wheel (tonewheel) (4) for the CMP is located at the front of the camshaft for the right cylinder head (2). This sync signal generator detects notches (1) located on a tonewheel. As the tonewheel rotates, the notches pass through the sync signal generator. The signal from the CMP sensor is used in conjunction with the Crankshaft Position Sensor (CKP) to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders.

When the leading edge of the tonewheel notch enters the tip of the CMP, the interruption of magnetic field causes the voltage to switch high, resulting in a sync signal of approximately 5 volts.

When the trailing edge of the tonewheel notch leaves the tip of the CMP, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts.

GAS ENGINES - 4.7L

The CMP sensor engine contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects notches located on a tonewheel. The tonewheel (4) is located at the front of the camshaft for the right cylinder head (2). As the tonewheel rotates, the notches (1) pass through the sync signal generator. The pattern of the notches (viewed counter-clockwise from front of engine) is: 1 notch, 2 notches, 3 notches, 3 notches, 2 notches, 1 notch, 3 notches and 1 notch. The signal from 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.

Scheme 27

The Camshaft Position Sensor (CMP) (1) is located on right side of timing gear/chain cover (2) near engine thermostat housing.

Scheme 28

1. Disconnect air resonator clamps at throttle body and also at air filter housing. Remove air resonator.
2. Disconnect electrical connector (4) at CMP sensor.
3. Remove sensor mounting bolt (3).
4. Carefully twist sensor (2) from timing gear/chain cover (1).
5. Check condition of sensor O-ring.

Scheme 29

The Camshaft Position Sensor (CMP) (2) is bolted to the front/top of the right cylinder head (1).

1. Raise and support vehicle.
2. Disconnect electrical connector (4) at CMP sensor.
3. Remove sensor mounting bolt (3).
4. Carefully twist sensor from cylinder head.
5. Check condition of sensor O-ring.

Scheme 30

The Camshaft Position Sensor (CMP) (3) is bolted to the front/top of the right cylinder head (1).

1. Disconnect electrical connector at CMP sensor.
2. Remove sensor mounting bolt (2).
3. Carefully twist sensor from cylinder head.
4. Check condition of sensor O-ring.

1. Clean out machined hole in timing gear/chain cover.
2. Install sensor (2) into timing gear/chain cover 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 timing gear/chain cover. If sensor is not flush, damage to sensor mounting tang may result.
3. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.).
4. Connect electrical connector (4) to sensor (1).
5. Install air resonator and tighten clamps.

GAS ENGINES - 3.7L

1. Clean out machined hole in cylinder head.
2. Apply a small amount of engine oil to sensor O-ring.
3. Install sensor (3) into cylinder head (1) with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder head. If sensor is not flush, damage to sensor mounting tang may result.
4. Install mounting bolt (2) and tighten to 12 N.m (106 in. lbs.).
5. Connect electrical connector to sensor.

1. Clean out machined hole in cylinder head.
2. Apply a small amount of engine oil to sensor O-ring.
3. Install sensor (2) into cylinder head (1) 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 head. If sensor is not flush, damage to sensor mounting tang may result.
4. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.).
5. Connect electrical connector to sensor.

Scheme 31

The 3.7L engine uses 6 dedicated, and individually fired coils (1) for each spark plug.

Scheme 32

Each coil (1) is mounted directly into the cylinder head and onto the top of each spark plug.

Scheme 33

The 5.7L engine uses 8 dedicated and individually fired coils (3) for each pair of spark plugs.

Each coil (3) is mounted directly to the top of each spark plug. Each coil is bolted (2) to the valve cover (4).

Scheme 34

The 4.7L uses 8 dedicated, and individually fired coil (1) for each spark plug. Each coil is mounted directly to the top of each spark plug.

COIL-IGNITION -3.7L/4.7L

Battery voltage is supplied to the six individual ignition coils from the ASD relay. The Powertrain Control Module (PCM) opens and closes each ignition coil ground circuit at a determined time for ignition coil operation.

Base ignition timing is not adjustable. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions.

The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine.

Because of coil design, spark plug cables (secondary cables) are not used.

COIL-IGNITION-5.7L

The ignition system is controlled by the Powertrain Control Module (PCM) on all engines.

The 5.7L engine uses dual output coils, and 2 spark plugs per cylinder.

Each cylinder is equipped with 1 dual-output coil. Meaning one coil mounts directly over one of the dual spark plugs for 1 high-voltage output.

Battery voltage is supplied to all of the ignition coils positive terminals from the ASD relay. If the PCM does not see a signal from the crankshaft and camshaft sensors (indicating the ignition key is ON but the engine is not running), it will shut down the ASD circuit.

Base ignition timing is not adjustable. By controlling the coil ground circuits, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions.

The PCM adjusts ignition timing based on inputs it receives from

1. The engine coolant temperature sensor
2. The crankshaft position sensor (engine speed)
3. The camshaft position sensor (crankshaft position)
4. The manifold absolute pressure (MAP) sensor
5. The throttle position sensor
6. Transmission gear selection

Scheme 35

1. Disconnect the electrical connector (1) from coil (3).
2. Clean area at base of coil with compressed air before removal.
3. Remove two mounting bolts (2) (note that mounting bolts are retained to coil).
4. Carefully pull up coil (1) from valve cover.
5. Remove coil (1) from vehicle.

COIL-IGNITION-3.7L

An individual ignition coil (1) is used for each spark plug. The coil fits into machined holes in the cylinder head. A mounting stud/nut secures each coil to the top of the intake manifold. The bottom 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 (2) is used to seal the coil at the opening into the cylinder head.

Scheme 36

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 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 (2) from mounting stud.
5. Carefully pull up coil from cylinder head opening with a slight twisting action.
6. Remove coil from vehicle.

COIL-IGNITION-4.7L

An individual ignition coil (1) is used for each spark plug. The coil fits into machined holes in the cylinder head. A mounting stud/nut (3) secures each coil to the top of the intake manifold . The bottom 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 is used to seal the coil at the opening into the cylinder 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 (2) 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 (3) from mounting stud.
5. Carefully pull up coil from cylinder head opening with a slight twisting action.
6. Remove coil from vehicle.

1. Using compressed air, blow out any dirt or contaminants from around top of spark plug.
2. Check condition of coil O-ring (2) and replace as necessary. To aid in coil installation, apply silicone to coil O-ring (2).
3. Position ignition coil into cylinder head opening and push onto spark plug. Do this while guiding coil base over mounting stud.
4. Install coil mounting stud nut (3). Tighten to 8 N.m (70 in.lbs).
5. Connect electrical connector (2) to coil by snapping into position.
6. If necessary, install throttle body air tube.

1. Using compressed air, blow out any dirt or contaminants from around top of spark plug. NOTE: Use dielectric grease on each of the spark plug boots before installing the coil.
2. Position ignition coil (1) into valve cover and push onto spark plugs.
3. Install 2 coil mounting bolts (2). Tighten to 7 N.m (62 in.lbs.).
4. Connect electrical connector (1) to coil by snapping into position.

Scheme 37

1. Using compressed air, blow out any dirt or contaminants from around top of spark plug.
2. Check condition of coil O-ring (2) and replace as necessary. To aid in coil installation, apply silicone to coil O-ring (2).
3. Position ignition coil (1) into cylinder head opening and push onto spark plug. Do this while guiding coil base over mounting stud.
4. Install coil mounting stud nut (2). Tighten to 8 N.m (70 in.lbs).
5. Connect electrical connector to coil by snapping into position.
6. If necessary, install throttle body air tube.

SENSOR-KNOCK

Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L & 4.7L.

Two knock sensors are also used with the 5.7L . These are bolted into each side of the cylinder block (outside) under the exhaust manifold.

Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount.

Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases.

The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard.

The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed.

Knock retard uses its own short term and long term memory program.

Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated.

Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as RPM is above the minimum RPM) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off.

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.

Scheme 38

The two knock sensors (1) are bolted into the cylinder block under the intake manifold (3).

Note. The left sensor is identified by an identification tag (LEFT). It is also identified by a larger bolt head. The Powertrain Control Module (PCM) must have and know the correct sensor left/right positions. Do not mix the sensor locations.

1. Disconnect knock sensor dual pigtail harness from engine wiring harness. This connection is made near rear of engine.
2. Remove intake manifold. Refer to «REMOVAL»(ref-288233-S36083521932008062000000) .
3. Remove sensor mounting bolts (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
4. Remove sensors (1) from engine.

Scheme 39

The two knock sensors (1) are bolted into the cylinder block under the intake manifold. The two sensors share a common wiring harness using one electrical connector (3). Because of this, they must be replaced as a pair.

Note. The left sensor is identified by an identification tag (LEFT) (2). It is also identified by a larger bolt head. The Powertrain Control Module (PCM) must have and know the correct sensor left/right positions. Do not mix the sensor locations.

1. Remove intake manifold. Refer to «INSTALLATION»(ref-288233-S10540832052008062000000) .
2. Disconnect knock sensor dual pigtail harness from engine wiring harness. This connection is made near rear of engine.
3. Remove both sensor mounting bolts. Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
4. Remove sensors from engine.

Scheme 40

Two sensors (1) are used. Each sensor is bolted into the outside of cylinder block below the exhaust manifold (3).

1. Raise vehicle.
2. Disconnect knock sensor electrical connector (5).
3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
4. Remove sensor from engine.

SENSOR-KNOCK-5.7L

1. Thoroughly clean knock sensor mounting hole.
2. Install sensor (1) into cylinder block (3). 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 for the knock sensor bolt is relatively light for an 8 mm bolt (2). NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.
3. Install and tighten mounting bolt (2). Tighten to 15 +/- 2 ft. lbs. (20 N.m) (176 in.lbs.).
4. Install electrical connector to sensor (5).

Resistor type spark plugs are used on all engines.

Sixteen spark plugs (2 per cylinder) are used with 5.7L engines.

To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used.

Always use the recommended torque when tightening spark plugs. This is especially true when plugs are equipped with tapered seats. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head.

Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in LUBRICATION & MAINTENANCE article .

Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled.

Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. See REMOVAL .

1. Remove necessary air filter tubing at throttle body.
2. Prior to removing ignition coil, spray compressed air around coil base at cylinder head.
3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber.
4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. Also check condition of ignition coil O-ring and replace as necessary.
5. Inspect spark plug condition.

Scheme 41

The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap.

Adjust spark plug gap with a gap gauging tool (1).

Note. The 4.7L 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 substituted, 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 electrodes 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.

1. Start the spark plug into the cylinder head by hand to avoid cross threading.
2. Tighten spark plugs to 27 N.m (20 ft.lbs.). 3.7L & 4.7L.
3. The 5.7L is equipped with torque critical design spark plugs. Do not exceed 15 ft. lbs. torque. Tighten spark plugs to 18 N.m (13 ft.lbs). NOTE: 5.7L does not use an o-ring
4. Before installing ignition coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring.
5. Install ignition coil(s). See «INSTALLATION»(ref-288263-S09670824282008062000000) .

KEY/LOCK CYLINDER

The key lock cylinder may be removed without removing the switch assembly, although the original ignition key must be used.

Scheme 42

Scheme 43

Scheme 44

1. Disconnect negative cable from battery.
2. Use a plastic trim removal stick (2) to remove switch bezel (1). Bezel snaps on.
3. To remove key lock cylinder (1) from housing (2), rotate key to ON position while pressing on release tab (3). This tab (3) is located on the right side of the switch assembly.
4. Pull key lock cylinder (1) from housing (2) for removal.

1. Install ignition key into lock cylinder (1). Rotate key to "ON" position (retaining tab on side of lock cylinder (3) can now be depressed).
2. The shaft at end of key lock cylinder aligns with socket within end of housing. To align socket with lock cylinder, ensure socket is in "ON" position.
3. Position and align key lock cylinder with grooves in housing.
4. Slide lock cylinder into housing until release tab (3) sticks through opening at side of housing.
5. Install bezel (1). Snaps on.
6. Connect negative battery cable.

IGNITION SWITCH

The electrical ignition switch attaches to the rear of the key lock cylinder housing. The SKREEM unit also attaches to the key lock cylinder housing. For ignition switch terminal and circuit identification, refer to the SYSTEM WIRING DIAGRAMS article.

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

1. Disconnect negative cable from battery.
2. Use a plastic trim removal stick (2) to remove switch bezel (1). Bezel snaps on.
3. Remove silencer pad (1) (two screws).
4. Remove knee blocker (1). Refer to «REMOVAL»(ref-288230-S16948167922008062000000) .
5. Remove two key cylinder housing Torx screws (2).
6. Use a plastic trim removal stick (2) to remove I.P. cluster bezel (1). Bezel snaps on. Refer to «REMOVAL»(ref-288230-S18104262342008062000000) .
7. Remove one key cylinder housing Torx screw (1).
8. To prevent binding or kinking cable (2), carefully lower the key/cylinder/switch/cable/SKREEM assembly (1). Disconnect two electrical connectors (one at ignition switch and one at SKREEM). To release cable (2) from switch, simultaneously press on tab (3) while pressing on tab.
9. Remove SKREEM unit (2) from switch housing (3) by removing screw (1).
10. Remove ignition switch (2) from switch housing (1) by removing screw (4) and then proceeding to the next step.
11. Continue to remove ignition switch (2) by simultaneously pressing on two release tabs using two small screwdrivers (1), while pulling ignition switch (2) from housing (3).
12. To remove key lock cylinder (1) from housing (2), rotate key to ON position while pressing on release tab (3).
13. Remove key lock cylinder (1) from housing (2).

Scheme 54

1. Install ignition key into lock cylinder (1). Rotate key to "ON" position (retaining tab on side of lock cylinder (3) can now be depressed).
2. The shaft at end of key lock cylinder aligns with socket within end of housing. To align socket with lock cylinder, ensure socket is in "ON" position.
3. Position and align key lock cylinder with grooves in housing.
4. Slide lock cylinder into housing until release tab (3) sticks through opening at side of housing.
5. Install ignition switch (2) to switch housing (1) until it snaps into the two tabs. Install and tighten screw (4).
6. Install SKREEM unit (2) to switch housing (3) and install screw (1).
7. Position cable into assembly until tab (1) engages.
8. Install one key cylinder housing Torx screw (1). Do not tighten (finger tight only).
9. Install two key cylinder housing Torx screws (2). Now tighten all three housing mounting screws.
10. Install knee blocker. Refer to «INSTALLATION»(ref-288230-S07127138412008062000000) .
11. Install silencer pad.
12. Install both bezel. Snaps on. Refer to «INSTALLATION»(ref-288230-S30814846252008062000000) .
13. Connect negative battery cable.

Scheme 55

Glow plugs are used to help start a cold or cool engine. (Scheme 55) 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. Each glow plug is threaded into the side of the cylinder head below the cylinder head cover.

GLOW PLUG

The glow plugs are used to preheat the combustion chambers in order to achieve the ignition temperature required for the fuel-air mixture.

The glow plug consists of a housing with a female thread and an interference-fit rod. The heating element is integrated in the glow rod. It consists of a heating winding and a control winding connected in series.

When the glow plug system is switched "ON", a current of about 30 ampere flows to each glow plug. The heating winding heats the glow plug. The control winding increases its resistance as the temperature rises and limits the current to approximately 15-25 ampere. The glow plug is protected this way from overloads.

1. Disconnect negative battery cable.
2. Remove engine cover. Refer to «REMOVAL»(ref-288233-S12765273522008062000000) .
3. Disconnect glow plug electrical connector (1). WARNING: Risk of injury to skin and eyes from handling hot or glowing objects. Wear protective gloves, clothing and eye wear.
4. Clean glow plug bay.
5. Remove glow plugs.

1. Install glow plug. Tighten glow plugs to 12 Nm (106 lbs. in.).
2. Connect glow plug electrical connector (1).
3. Install engine cover. Refer to «INSTALLATION»(ref-288233-S35221246932008062000000) .
4. Connect negative battery cable.