Dodge Ignition Control 3500 2005, Ignition Control 2500 2005, Ignition Control 1500 2005 Service Manual

DR/DH IGNITION CONTROL 8I - 1

IGNITION CONTROL

TABLE OF CONTENTS

page page

IGNITION CONTROL - ELECTRICAL

DIAGNOSTICS ........................... 1

IGNITION CONTROL - SERVICE INFORMATION .. 5

IGNITION CONTROL - ELECTRICAL DIAGNOSTICS

TABLE OF CONTENTS

page

IGNITION CONTROL - ELECTRICAL

DIAGNOSTICS

DIAGNOSIS AND TESTING

IGNITION RUN/START MISMATCH (FCM) ....2

IGNITION CONTROL - ELECTRICAL DIAGNOSTICS

DIAGNOSIS AND TESTING

8I - 2 IGNITION CONTROL - ELECTRICAL DIAGNOSTICS DR/DH

IGNITION RUN/START MISMATCH (FCM)

DR/DH IGNITION CONTROL - ELECTRICAL DIAGNOSTICS 8I - 3

IGNITION RUN/START MISMATCH (FCM) (CONTINUED)

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on.

• Set Condition:

The FCM detects an ignition run/start mismatch.

Possible Causes

INSTRUMENT CLUSTER POWER DISTRIBUTION CENTER FRONT CONTROL MODULE

Diagnostic Test

CHECK FOR AN ACTIVE DTC

Turn the ignition on. With the DRB, erase the FCM DTC’s. Turn the ignition off then turn the ignition on and wait approximately 1 minute. With the DRB, read the FCM DTC’s.

Did this DTC reset?

Yes >> No >>

CHECK THE STATUS OF THE INSTRUMENT CLUSTER

NOTE: Ensure the battery is fully charged before proceeding with this test. NOTE: Diagnose and repair any Airbag, Instrument Cluster, or PCM DTCs before proceeding with this test.

With the DRB, select MIC, Monitors and observe the ignition state. While observing the ignition state, start the vehicle.

Does the DRB display run and start when the ignition switch is in those positions?

Yes >> No >>

Go To 2 The condition that set this DTC is no longer present. Using the wiring diagram/schematic as a guide,

inspect the wiring for chafed, pierced, pinched, and partially broken wires and the wiring harness connectors for broken, bent, pushed out, and corroded terminals.

Go To 3 Replace and program the Instrument Cluster in accordance with the service information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

8I - 4 IGNITION CONTROL - ELECTRICAL DIAGNOSTICS DR/DH

IGNITION RUN/START MISMATCH (FCM) (CONTINUED)

CHECK THE FUSED IGNITION SWITCH OUTPUT CIRCUIT

NOTE: Check IPM fuse #50 for an open before proceeding with this test.

Turn the ignition off. Remove the FCM from the IPM. Turn the ignition on. Using a 12-volt test light connected to ground, probe the Fused Igni-

tion Switch Output circuit (cavity 48).

Is the test light illuminated?

Yes >>

No >>

Replace the Front Control Module in accordance with the service information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

Replace the Power Distribution Center in accordance with the service information.

Perform BODY VERIFICATION TEST - VER 1. (Refer to BODY VERIFICATION TEST - VER 1.)

DR/DH IGNITION CONTROL - SERVICE INFORMATION 8I - 5

IGNITION CONTROL - SERVICE INFORMATION

TABLE OF CONTENTS

page page

IGNITION CONTROL - SERVICE INFORMATION

DESCRIPTION ..........................5

SPECIFICATIONS

TORQUE .............................7

ENGINE FIRING ORDER - 3.7L V-6 .........8

ENGINE FIRING ORDER – 4.7L V-8 ........8

FIRING ORDER / CABLE ROUTING – 5.7L

V-8 ENGINE ...........................8

8.3L - FIRING ORDER ...................9

SPARK PLUG CABLE RESISTANCE .......10

SPARK PLUGS .......................10

IGNITION COIL RESISTANCE - 3.7L V-6 ....10

IGNITION COIL RESISTANCE - 4.7L V-8 ....10

IGNITION COIL RESISTANCE - 5.7L V-8 ....11

IGNITION COIL RESISTANCE - 8.3L V-10 . . . 11

IGNITION TIMING .....................11

RELAY-AUTO SHUT DOWN

DESCRIPTION - PCM OUTPUT .............11

OPERATION

OPERATION - PCM OUTPUT .............11

OPERATION - ASD SENSE - PCM INPUT . . . 11

DIAGNOSIS AND TESTING - ASD AND FUEL

PUMP RELAYS .......................11

REMOVAL .............................13

INSTALLATION .........................13

SENSOR-CAMSHAFT POSITION

DESCRIPTION .........................13

OPERATION

OPERATION .........................14

8.3L V-10 ............................16

REMOVAL

REMOVAL ...........................17

8.3L - REPLACING WITH NEW SENSOR ....19

8.3 L - REPLACING OLD SENSOR WITH

ORIGINAL ...........................20

INSTALLATION

INSTALLATION .......................20

8.3L - INSTALLATION - WITH NEW SENSOR . 21

8.3L - REPLACING OLD SENSOR WITH

ORIGINAL ...........................21

IGNITION COIL

DESCRIPTION .........................23

OPERATION ...........................25

REMOVAL

REMOVAL ...........................26

8.3L - SRT-10 .........................29

INSTALLATION

INSTALLATION .......................30

8.3L - SRT-10 .........................31

SENSOR-KNOCK

DESCRIPTION .........................31

OPERATION ...........................31

REMOVAL .............................32

INSTALLATION .........................33

SPARK PLUG

DESCRIPTION .........................34

REMOVAL .............................34

CLEANING

CLEANING AND ADJUSTMENT ...........35

INSTALLATION .........................35

IGNITION COIL CAPACITOR

DESCRIPTION .........................36

OPERATION ...........................36

REMOVAL .............................36

INSTALLATION .........................37

SPARK PLUG CABLE

DESCRIPTION .........................37

OPERATION ...........................37

REMOVAL

REMOVAL ...........................37

8.3L - SRT-10 .........................38

INSTALLATION

INSTALLATION .......................38

8.3L - SRT-10 .........................39

PUSH-BUTTON STARTER SWITCH

DESCRIPTION .........................40

REMOVAL .............................41

INSTALLATION .........................41

IGNITION CONTROL - SERVICE INFORMATION

DESCRIPTION

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

3.7L V-6 ENGINE

The 3.7L V-6 engine uses a separate ignition coil 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.

8I - 6 IGNITION CONTROL - SERVICE INFORMATION DR/DH

Because of coil design, spark plug cables (secondary cables) are not used. A distributor is not used with the 3.7L engine.

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:

• 6 Spark Plugs

• 6 Separate Ignition Coils

• 2 Knock Sensors

• Powertrain Control Module (PCM)

• 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

4.7L V-8 ENGINE

The 4.7L V-8 engine uses a separate ignition coil 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 with the 4.7L engine.

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:

• 8 Spark Plugs

• 8 Separate Ignition Coils

• 2 Knock Sensors

• Powertrain Control Module (PCM)

• 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

5.7L V-8 ENGINE

For additional information, also refer to Ignition Coil Description and Operation.

The 5.7L V-8 engine 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 the coils secondary output terminal directly to a spark plug using a rubber boot seal. Each coil is also equipped with a second output terminal. This second terminal connects a conventional spark plug cable directly to a spark plug on the opposite cylinder bank. A separate primary electrical connector is used for each coil.

Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss-match of cables, a corresponding spark plug / coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body.

Two knock sensors (one for each cylinder bank) are used to help control spark knock. The 5.7L engine will not use a conventional distributor.

DR/DH IGNITION CONTROL - SERVICE INFORMATION 8I - 7

The ignition system consists of:

• 16 Spark Plugs (2 per cylinder)

• 8 Separate, Dual-Secondary Output, Ignition

Coils

• 2 Knock Sensors

• 8 Secondary Ignition Cables

• Powertrain Control Module (PCM)

• 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

SPECIFICATIONS TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Camshaft Position Sensor

- 3.7L V-6 Engine

Camshaft Position Sensor

- 4.7L V-8 Engine

Camshaft Position Sensor

- 5.7L V-8 Engine

Camshaft Position Sensor

- 8.3L Engine

Crankshaft Position

Sensor - 3.7L V-6 Engine

Crankshaft Position

Sensor - 4.7L V-8 Engine

Crankshaft Position

Sensor - 5.7L V-8 Engine

Crankshaft Position

Sensor - 8.3L Engine

Ignition Coil Mounting -

3.7L V-6 Engine

Ignition Coil Mounting -

4.7L V-8 Engine

Ignition Coil Mounting -

5.7L V-8 Engine

Ignition Coil to Cyl. Head

Screws 8.3L Engine

* Knock Sensor - 3.7L V-6

Engine

12 - 106

12 9 105

10.7 - 95

28 21 205

12 9 105

10.7 - 95

8-70

12 9 105 (± 20)

10.7 - 95

20 15 176

8I - 8 IGNITION CONTROL - SERVICE INFORMATION DR/DH

DESCRIPTION N·m Ft. Lbs. In. Lbs.

* Knock Sensor - 4.7L V-8

Engine

* Knock Sensor - 5.7L V-8

Engine

Spark Plugs - 3.7L V-6

Engine

Spark Plugs - 4.7L V-8

Engine

** Spark Plugs - 5.7L V-8

Engine

Spark Plugs - 8.3L Engine 27 20 -

* Do not apply any sealant, thread-locker or adhesive to bolts. Poor sensor performance may result.

** Torque critical tapered design. Do not exceed 15 ft. lbs.

20 15 176

27 20 -

18 (± 3) 13 (± 2) -

ENGINE FIRING ORDER - 3.7L V-6

1-6-5-4-3-2

ENGINE FIRING ORDER – 4.7L V-8

FIRING ORDER / CABLE ROUTING –

5.7L V-8 ENGINE

Eight conventional spark plug cables are used with the

5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylinder bank. The cables are placed and routed in a special plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a missmatch of cables, a corresponding spark plug / coil number is displayed on each plug cable: 1/6, 2/3, 4/7 and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body.

DR/DH IGNITION CONTROL - SERVICE INFORMATION 8I - 9

8.3L - FIRING ORDER

1-10-9-4-3-6-5-8-7-2

8I - 10 IGNITION CONTROL - SERVICE INFORMATION DR/DH

SPARK PLUG CABLE RESISTANCE

Except 8.3L V-10

MINIMUM MAXIMUM

250 Ohms Per Inch 1000 Ohms Per Inch

3000 Ohms Per Foot 12,000 Ohms Per Foot

8.3L V - 10

MINIMUM MAXIMUM

250 Ohms Per Inch 750 Ohms Per Inch

3000 Ohms Per Foot 9,000 Ohms Per Foot

SPARK PLUGS

ENGINE PLUG TYPE ELECTRODE GAP

3.7L V-6 ZFR6F - 11G (NGK) 1.1 (0.042 in.)

4.7L V-8 RC12MCC4 1.01 mm (.040 in.)

5.7L V-8 Champion - RE14MCC4 1.14 mm (.045 in.)

8.3L V-10 RC12ECC 0.033 to 0.038

IGNITION COIL RESISTANCE - 3.7L V-6

PRIMARY RESISTANCE

21-27°C (70-80°F)

0.6 - 0.9 Ohms 6,000 - 9,000 Ohms

SECONDARY

RESISTANCE 21-27°C

(70-80°F)

IGNITION COIL RESISTANCE - 4.7L V-8

PRIMARY

RESISTANCE 21-27°C

(70-80°F)

0.6 - 0.9 Ohms 6,000 - 9,000 Ohms

SECONDARY

RESISTANCE 21-27°C

(70-80°F)

DR/DH IGNITION CONTROL - SERVICE INFORMATION 8I - 11

IGNITION COIL RESISTANCE - 5.7L V-8

PRIMARY RESISTANCE @ 21-27°C (70-80°F)

0.558 - 0.682 Ohms

(Plus or Minus 10% @ 70-80° F)

IGNITION COIL RESISTANCE - 8.3L V-10

Coil Manufacture Diamond 0.53 to 0.65 Ohms 10,900 to 14,700 Ohms

Primary Resistance at 21°C-27°C (70°F-80°F)

Secondary Resistance at 21°C-27°C (70°F-80°F)

IGNITION TIMING

Ignition timing is not adjustable on any engine.

RELAY-AUTO SHUT DOWN

DESCRIPTION - 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.

OPERATION OPERATION - PCM OUTPUT

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:

• the ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds.

• there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values.

OPERATION - ASD 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).

DIAGNOSIS AND TESTING - ASD AND FUEL PUMP RELAYS

The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used,

or.

8I - 12 IGNITION CONTROL - SERVICE INFORMATION DR/DH

• Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times.

• The PCM grounds the coil side of the relay through terminal number 85.

• Terminal number 86 supplies voltage to the coil side of the relay.

• When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay.

• When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal

30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit.

The following procedure applies to the ASD and fuel pump relays.

1. Remove relay from connector before testing.

2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms +/- 5 ohms.

3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A.

4. Connect the ohmmeter between terminals 87 and

30. The ohmmeter should not show continuity at this time.

5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source.

6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do

not attach the other end of the jumper wire to the relay at this time.

WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT.

7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30.

8. Disconnect jumper wires.

9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to 8, Wiring Diagrams.

DR/DH IGNITION CONTROL - SERVICE INFORMATION 8I - 13

REMOVAL

The ASD relay is located in the Power Distribution Center (PDC) (2) . 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.

INSTALLATION

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.

SENSOR-CAMSHAFT POSITION

DESCRIPTION

3.7L V-6

The Camshaft Position Sensor (CMP) on the 3.7L 6-cylinder engine is bolted to the right-front side of the right cylinder head.

4.7L V-8

The Camshaft Position Sensor (CMP) on the 4.7L V-8 engine is bolted to the right-front side of the right cylinder head.

5.7L V-8

The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the generator on the timing chain / case cover on the right/front side of engine.

5.9L Diesel

The Camshaft Position Sensor (CMP) on the 5.9L diesel engine is located below the fuel injection pump. It is bolted to the back of the timing gear cover.

+ 29 hidden pages