1996 CHRYSLER VOYAGER spark plugs

plugs.Ash encrusted spark plugs can be cleaned
and reused.
HIGH SPEED MISS
When replacing spark plugs because of a high
speed miss condition;wide open throttle opera-
tion should be avoided for approximately 80 km
(50 miles) after installation of new plugs.This
will allow deposit shifting in the combustion chamber
to take place gradually and avoid plug destroying
splash fouling shortly after the plug change.
ELECTRODE GAP BRIDGING
Loose deposits in the combustion chamber can
cause electrode gap bridging. The deposits accumu-
late on the spark plugs during continuous stop-
and-go driving. When the engine is suddenly
subjected to a high torque load, the deposits partially
liquefy and bridge the gap between the electrodes
(Fig. 25). This short circuits the electrodes.Spark
plugs with electrode gap bridging can be
cleaned and reused.
SCAVENGER DEPOSITS
Fuel scavenger deposits may be either white or yel-
low (Fig. 26). They may appear to be harmful, but
are a normal condition caused by chemical additives
in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease
spark plug misfire tendencies. Notice that accumula-
tion on the ground electrode and shell area may be
heavy but the deposits are easily removed.Spark
plugs with scavenger deposits can be consid-
ered normal in condition, cleaned and reused.
CHIPPED ELECTRODE INSULATOR
A chipped electrode insulator usually results from
bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions,
severe detonation also can separate the insulator
from the center electrode (Fig. 27).Spark plugs
with chipped electrode insulators must be
replaced.
PREIGNITION DAMAGE
Excessive combustion chamber temperature can
cause preignition damage. First, the center electrode
dissolves and the ground electrode dissolves some-
what later (Fig. 28). Insulators appear relatively
deposit free. Determine if the spark plugs are the
correct type, as specified on the VECI label, or if
other operating conditions are causing engine over-
heating.
SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center
electrode insulator that also appears blistered (Fig.
Fig. 24 Oil or Ash Encrusted
Fig. 25 Electrode Gap Bridging
Fig. 26 Scavenger Deposits
8D - 12 IGNITION SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

REMOVAL AND INSTALLATION
SPARK PLUG CABLE SERVICEÐ2.4L
The cables insulate the spark plugs and covers the
top of the spark plug tube (Fig. 6). To remove the
cables, lightly grasp the top of the cable. Rotate the
insulator 90É and pull straight up. To replace the
cables, disconnect the cable from the ignition coil.
Ensure the #1 and #4 cables run under the #2
and #3 ignition coil towers. Keep #4 cable away
from the oil fill cap.
SPARK PLUG SERVICE
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them inthe appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs orshort cir-
cuit the cables to ground.
Never Wire Brush Spark Plugs.The spark plug
insulator tip is harder than the bristles of wire
brushes. Bristles of wire brushes can leave a conduc-
tive, metallic film on the insulator which could lead
to conductive deposits. Conductive deposits can cause
spark plug failure and engine misfire. Use a jewelers
file to remove deposits from the electrode gap or use
a spark plug cleaning machine to clean spark plugs.
REMOVAL
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 com-
pressed 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. Refer to
Spark Plug Condition in this section.
INSTALLATION
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 N´m (20 ft. lbs.)
torque.
(3) Install spark plug cables over spark plugs. A
click will be heard and felt when the cable properly
attaches to the spark plug.
IGNITION COILÐ2.4L
REMOVAL
REMOVAL
(1) Remove spark plug cables from coil (Fig. 7).
Always twist the coil boots to break the seal with the
coil and pull straight back on the boot.
(2) Remove ignition coil electrical connector.
(3) Remove ignition coil mounting bolts, throttle
cable bracket or clip.
(4) Remove ignition coil.
INSTALLATION
(1) Reverse the above procedure for installation.
Tighten mounting screws to 12 N´m (105 in. lbs.)
torque.
(2) Transfer ignition cables to new coil pack. The
coil pack towers and cables are numbered with cylin-
der identification.
Fig. 5 Intake Air Temperature Sensor
Fig. 6 Spark Plug Cables
8D - 18 IGNITION SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

SPECIFICATIONS
IGNITION COIL
SPARK PLUG
TORQUE
DESCRIPTION......................TORQUE
2.4L Target Magnet Screw.......3N´m(30in.lbs.)
2.4L Camshaft Position Sensoe Screw . .9 N´m (80 in.
lbs.)
Ignition Switch...............2N´m(17in.lbs.)
Spark Plugs.................28N´m(60in.lbs.)
SPARK PLUG CABLE RESISTANCEÐ2.4L
Coil ManufacturePrimary Resistance at 21ÉC-27ÉC
(70ÉF-80ÉF)Secondary Resistance at 21ÉC-
27ÉC (70ÉF-80ÉF)
Weastec (Steel Towers) 0.45 to 0.65 Ohms 7,000 to 15,800 Ohms
Coil Polarity
Engine Spark Plug Gap Thread Size
2.4L RC12YC5 0.048 TO 0.053 14mm (3/4 in.) reach
CABLE Maximum
Resistance
#1 & #4 4.2K ohms
#2 & #3 3.2K ohms
8D - 22 IGNITION SYSTEMNS

REMOVAL AND INSTALLATION
SPARK PLUG SERVICE
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 orshort cir-
cuit the cables to ground.
Never Wire Brush Spark Plugs.The spark plug
insulator tip is harder than the bristles of wire
brushes. Bristles of wire brushes can leave a conduc-
tive, metallic film on the insulator which could lead
to conductive deposits. Conductive deposits can cause
spark plug failure and engine misfire. Use a jewelers
file to remove deposits from the electrode gap or use
a spark plug cleaning machine to clean spark plugs.
REMOVAL
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 com-
pressed 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. Refer to
Spark Plug Condition in this section.
INSTALLATION
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 N´m (20 ft. lbs.)
torque.
(3) Install spark plug cables over spark plugs. A
click will be heard and felt when the cable properly
attaches to the spark plug.
IGNITION COILÐ3.OL
The ignition coil is located at the back of the
intake manifold (Fig. 2).
REMOVAL
(1) Remove air cleaner assembly.
(2) Disconnect ignition cable from coil.
(3) Disconnect wiring harness connector from coil.
(4) Remove coil mounting screws.
INSTALLATION
(1) Loosely install ignition coil on intake manifold.
Tighten the intake manifold fastener to 13 N´m (115
in. lbs.) torque. Tighten ignition coil bracket fasten-
ers to 10 N´m (96 in. lbs.) torque.
(2) Connect the wiring harness connector.
(3) Connect the coil to distributor ignition cable.
(4) Install the air cleaner assembly. Tighten the
air cleaner fasteners to 25 N´m (225 in. lbs.) torque.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ3.0L
REMOVAL
(1) Remove vacuum hose and mounting screws
from manifold absolute pressure (MAP) sensor (Fig.
3).
(2) Disconnect electrical connector from sensor.
Remove sensor.
Fig. 1 Camshaft Position SensorÐ3.0L Engine
Fig. 2 Ignition CoilÐ3.0L Engine
8D - 24 IGNITION SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

When replacing the distributor cap, transfer spark
plug wires from the original cap to the new cap one
at a time. Ensure that each wire is installed into the
tower of the new cap that corresponds to its tower
position in the original cap. Fully seat the wires into
the towers. If necessary, refer to the engine firing
order diagram.
Light scaling of the terminals can be cleaned with
a sharp knife. If the terminals are heavily scaled,
replace the distributor cap.
A cap that is greasy, dirty or has a powder-like
substance on the inside should be cleaned with asolution of warm water and a mild detergent. Scrub
the cap with a soft brush. Thoroughly rinse the cap
and dry it with a clean soft cloth.
DISTRIBUTOR ROTORÐ3.0L
Replace the rotor if it is cracked, the tip is exces-
sively burned or heavily scaled (Fig. 10).
SPECIFICATIONS
SPARK PLUG
TORQUE
DESCRIPTION......................TORQUE
Distributor Hold Down........14N´m(124 in. lbs.)
Ignition Coil Bracket..........10N´m(96in.lbs.)
Ignition Switch...............2N´m(17in.lbs.)
Spark Plugs.................28N´m(60in.lbs.)
SPARK PLUG CABLE RESISTANCEÐ3.0L
Fig. 9 Distributor Cap InspectionÐTypical
Fig. 10 Rotor InspectionÐTypical
Engine Spark Plug Gap Thread Size
3.0L RN11YC4 0.039 TO 0.044 14mm (3/4 in.) reach
CABLE Maximum
Resistance
#1 14.0K ohms
#2 10.4K ohms
#3 14.9K ohms
#4 11.5K ohms
#5 17.5K ohms
#6 10.3K ohms
Coil Lead 11.1K ohms
NSIGNITION SYSTEM 8D - 27
CLEANING AND INSPECTION (Continued)

3.3/3.8L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
FIRING ORDERÐ3.3/3.8L................. 28
REMOVAL AND INSTALLATION
CAMSHAFT POSITION SENSOR............ 31
CRANKSHAFT POSITION SENSOR.......... 30
ENGINE COOLANT TEMPERATURE SENSOR . . 32
IGNITION COIL......................... 30
KNOCK SENSORÐ3.3/3.8L................ 32
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR............................. 32SPARK PLUG CABLE SERVICEÐ3.3/3.8L
ENGINES............................ 28
SPARK PLUG SERVICEÐ3.3/3.8L ENGINES . . . 29
THROTTLE POSITION SENSOR............ 32
SPECIFICATIONS
IGNITION COIL......................... 33
SPARK PLUG CABLE RESISTANCEÐ3.3/3.8L . . 34
SPARK PLUG........................... 33
TORQUE.............................. 34
DESCRIPTION AND OPERATION
FIRING ORDERÐ3.3/3.8L
The firing order for 3.3L and 3.8L engines is 1-2-3-
4-5-6.
REMOVAL AND INSTALLATION
SPARK PLUG CABLE SERVICEÐ3.3/3.8L ENGINES
WARNING: The ignition cables should not be
removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the
ignition cables.
The spark plug boot heat shield needs to be
installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly
engine misfire would occur.
Do not use pliers to pull the boot/heat shield
assembly from the spark plugs. This will damage the
shield assembly.
Spark plug boot heat shields must be replaced if
they are bent or damaged. It is extremely important
the shield is reinstalled correctly as shown. The bot-
tom of the spark plug heat shield must make contact
with the spark plug socket hex.
Firing OrderÐ3.3/3.8L
Fig. 1 Spark Plug Boot/Heat Shield Orientation
8D - 28 IGNITION SYSTEMNS

CAUTION: Never coat the inside of spark plug
boots with silicone grease. Some types of silicone
grease can damage the ignition cable conductor.
SPARK PLUG CABLES #3 AND #5
REMOVAL
(1) Remove the resonator.
(2) Grasp the spark plug boot/heat shield as close
as possible to the spark plug.Twist the boot
slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the
ignition cable, or pull the spark plug boot at an
angle.This could damage the spark plug insulator,
terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
(3) Remove the cable from the retaining bracket.
Make sure that they are also detached from the rear
retaining clip mounted on the rear of the intake
manifold.
INSTALLATION
(1) When installing the spark plug cables, make
sure the coil and spark plug insulator and terminals
are fully seated. Aclick sound should be heard or
terminal engagement is felt when the terminals
are properly attached.
(2) Install the cable into the retaining bracket.
Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
(3) Install the resonator.
SPARK PLUG CABLE #1
REMOVAL
(1) Remove the accessory drive belt, refer to Group
7, Cooling.
(2) Remove the four bolts from the upper half of
the generator bracket.
(3) Push the Generator rearward.
(4) Grasp the spark plug boot/shield assembly as
close as possible to the spark plug.Twist the boot
slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the
ignition cable, or pull the spark plug boot at an
angle.This could damage the spark plug insulator,
terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
(5) Remove the cable from the retaining bracket.
INSTALLATION
(1) When installing the spark plug cables, make
sure the coil and spark plug insulator and terminals
are fully seated. Aclick sound should be heard orterminal engagement is felt when the terminals
are properly attached.
(2) Rotate Generator back into place.
(3) Install upper Generator bracket with the four
bolts.
(4) Install the accessory drive belt, refer to Group
7, Cooling.
SPARK PLUG SERVICEÐ3.3/3.8L ENGINES
WARNING: The ignition cables should not be
removed while the engine is hot. This could cause
server injury/burns and can cause damage to the
ignition cables.
Use extreme care when removing and installing
the spark plug cables.
The spark plug boot heat shield needs to be
installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly
engine misfire would occur.
Do not use pliers to pull the boot/heat shield
assembly from the spark plugs. This will damage the
shield assembly.
SPARK PLUG #3 AND #5
REMOVAL
(1) Remove the resonator.
(2) Remove intake strut to cylinder head bolt at
cylinder head.
(3) Loosen bolt for intake strut at intake.
(4) Swing strut away.
(5) Grasp the spark plug boot/shield assembly as
close as possible to the spark plug.Twist the boot/
shield assembly slightly to break the seal with
the plug and pull straight out. Do not use pli-
ers, pull on the ignition cable, or pull the spark
plug boot at an angle.This could damage the
spark plug insulator, terminal, heat shield or the
insulation. Wipe spark plug insulator clean with a
dry cloth before installation.
(6) Remove spark plug
INSTALLATION
(1) Install spark plug and tighten to 28 N´m (20 ft.
lbs.).
(2) When installing the spark plug cables, make
sure spark plug insulator and terminals are fully
seated. Aclick sound should be heard or felt
when the terminals are properly attached.
(3) Install the cable into the retaining bracket.
Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
(4) Swing strut back into place.
NSIGNITION SYSTEM 8D - 29
REMOVAL AND INSTALLATION (Continued)

SPARK PLUG
* New Spark Plug Gap
TORQUE
DESCRIPTION......................TORQUE
3.3L Camshaft Position
Sensor Screw.............12N´m(105 in. lbs.)
3.3L Engine Coolant Sensor......7N´m(60in.lbs.)
3.3L Crankshaft Position
Sensor Screw.............12N´m(105 in. lbs.)
3.3/3.8L Ignition Coil.........12N´m(105 in. lbs.)
Ignition Switch...............2N´m(17in.lbs.)
Spark Plugs.................28N´m(20ft.lbs.)
SPARK PLUG CABLE RESISTANCEÐ3.3/3.8L
Engine Spark Plug Gap * Thread Size
3.3L RN14PMP5 0.048 TO 0.053 14mm (3/4 in.) reach
3.8L RN14PMP5 0.048 TO 0.053 14mm (3/4 in. ) reach
CABLE Maximum
Resistance
#1 18.5K ohms
#2 15.5K ohms
#3 20.4K ohms
#4 21.2K ohms
#5 27.7K ohms
#6 26.7K ohms
8D - 34 IGNITION SYSTEMNS
SPECIFICATIONS (Continued)