300, Magnum, 2005

Ignition Coil

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Removal & Installation



2.7L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold.
    NOTE
    Before removing the ignition coils, spray compressed air around the coil area and spark plug to remove any dirt or debris.

  4.  
  5. Detach the electrical connector from the ignition coil.
  6.  
  7. Remove the 2 fasteners from ignition coil assembly.
  8.  
  9. Remove the ignition coil assembly.

    Click image to see an enlarged view

    Fig. Removing the ignition coil-2.7L engine shown, 3.5L engine similar

  10.  

To install:

  1. Install the ignition coil assembly to the spark plug.
  2.  
  3. Install the coil screws and tighten to 55 inch lbs. (6.2 Nm.
  4.  
  5. Attach the electrical connector and lock.
  6.  
  7. Install the intake manifold.
  8.  
  9. Connect the negative battery cable.
  10.  

3.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold.
    NOTE
    Before removing the ignition coils, spray compressed air around the coil area and spark plug to remove any dirt or debris.

  4.  
  5. Unlock and remove the electrical connector from the ignition coil.
    NOTE
    On 3.5L engines, it is necessary to loosen the screws by alternating back and forth. Do not lose the spacers under the coil when loosening the screws.

  6.  
  7. Remove the 2 fasteners from the ignition coil assembly.
  8.  
  9. Remove the ignition coil assembly.

    Click image to see an enlarged view

    Fig. Removing the ignition coil-2.7L engine shown, 3.5L engine similar

  10.  

To install:


NOTE
On 3.5L engines, it is necessary to tighten the screws by alternating back and forth. Do not lose the spacers under the coil when installing ignition coils.

  1. Install the ignition coil assembly to the spark plug.
  2.  
  3. Install the coil screws and tighten them to 60 inch lbs. (6.7 Nm.
  4.  
  5. Connect the electrical connector and lock.
  6.  
  7. Install the intake manifold.
  8.  
  9. Connect the negative battery cable.
  10.  

5.7L Engine

NOTE
Before removing or disconnecting any spark plug cables, note their original position. Remove cables one-at-a-time. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position.

An individual ignition coil is used at each cylinder. The coil mounts to the top of the valve cover with two bolts. 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.

Click image to see an enlarged view

Fig. View of the ignition coil (1), mounting bolts (2), and rubber boot (3)-5.7L engine

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.

  1. Disconnect the negative battery cable.
  2.  
  3. Unlock the electrical connector by moving the slide lock first. Press on release lock while pulling the electrical connector from coil.
  4.  
  5. Disconnect the secondary high-voltage cable from coil with a twisting action.
    NOTE
    Clean the area at the base of the ignition coil with compressed air before removal.

  6.  
  7. Remove the 2 ignition coil mounting bolts (note that the mounting bolts are secured to the coil).
  8.  
  9. Carefully pull the coil up from the cylinder head opening with a slight twisting action.
  10.  
  11. Remove the ignition coil from vehicle.
  12.  

Before installing spark plug cables to either the spark plugs or coils, or before installing a coil to a spark plug, apply dielectric grease to inside of boots.

Click image to see an enlarged view

Fig. Ignition coil (5) components-slide lock (1), secondary high-voltage cable (2), release lock (3), electrical connector (4), mounting bolts (6)

To install:

  1. Position the ignition coil into cylinder head opening and push the boot onto the spark plug. Twist coil into position.
  2.  
  3. Install the 2 coil mounting bolts and tighten to 105 inch lbs. (12 Nm)
  4.  
  5. Attach the electrical connector to the coil, then lock the connector.
  6.  
  7. Install the cable to the coil. To prevent ignition crossfire, the spark plug cables MUST be placed in cable tray (routing loom) into their original position.
  8.  
  9. If necessary, install throttle body air tube.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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