Aspen 2007, Durango 2006-2007

Spark Plugs

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Inspection




WARNING
The 4.7L V8 engine 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. The 5.7L V8 is equipped with torque critical design spark plugs. Do not exceed 15 ft. lbs. torque during installation.

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. Proper torque is especially important in the case of aluminum cylinder heads.

When replacing the spark plug and ignition coil 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. It could cause cross ignition of the spark plugs or short circuit the cables to ground.

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 can also separate the insulator from the center electrode. Spark plugs with this condition must be replaced.

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Fig. Chipped insulation (3) around center electrode (2) demands spark plug replacement.

Cold Fouling/Carbon Fouling

Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operating times (short trips).

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Fig. Normal operation with tan or light gray deposits (1). Cold fouling/carbon fouling with dry, black deposits (2), (3).

Electrode Gap Bridging

Electrode gap bridging may be traced to loose deposits in the combustion chamber. These deposits accumulate on the spark plugs during continuous stop-and-go driving. When the engine is suddenly subjected to a high torque load, deposits partially liquefy and bridge the gap between electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be cleaned using standard procedures.

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Fig. Deposits (2) bridging gap between ground electrode (1) and center electrode (3)

Normal Operation

The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed.

Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits.

Oil or Ash Encrusted

If one or more spark plugs are oil or oil ash encrusted, evaluate engine condition for the cause of oil entry into that particular combustion chamber.

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Fig. Oil or ash encrustation on electrodes

Preignition Damage

Preignition damage is usually caused by excessive combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Determine if the spark plug has the correct heat range rating for the engine. Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug. Spark plugs are designed to operate within specific temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator).

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Fig. Ground (1) and center (2) electrodes dissolving.

Scavenger Deposits

Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but this is 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 accumulation on the ground electrode and shell area may be heavy, but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard procedures.

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Fig. White or yellow deposits form on ground (1) or center (2) electrodes.

Spark Plug Overheating

Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 2000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition timing, detonation and cooling system malfunctions can also cause spark plug overheating.

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Fig. Blistered white or gray center electrode insulator (1).

Wet Fouling Or Gas Fouling

A spark plug coated with excessive wet fuel or oil is wet fouled. In older engines, worn piston rings, leaking valve guide seals or excessive cylinder wear can cause wet fouling. In new or recently overhauled engines, wet fouling may occur before break-in (normal oil control) is achieved. This condition can usually be resolved by cleaning and reinstalling the fouled plugs.

Removal & Installation



3.7L & 4.7L Engines

Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. Refer to Ignition Coil Removal/Installation. Prior to removing a spark plug, spray compressed air around base of the ignition coil at cylinder head. This will help prevent foreign material from entering combustion chamber.

  1. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert.
  2.  
  3. Inspect spark plug condition.
  4.  

To install:

  1. Start the spark plug into the cylinder head by hand to avoid cross threading.
  2.  
  3. Before installing coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring.
  4.  
  5. Tighten spark plugs to 20 ft. lbs. (27 Nm) torque.
  6.  
  7. Install ignition coil(s). Refer to Ignition Coil Removal/Installation.
  8.  

5.7L Engines

Sixteen spark plugs (2 per cylinder) are used with 5.7L V8 engines.

On 2005 models, eight of the 16 spark plugs are located under an ignition coil; the other 8 are not. If the spark plug being removed is under a coil, the coil must be removed to gain access to the spark plug. Refer to Ignition Coil Removal/Installation.

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. Refer to Spark Plug Cable Removal for proper routing.

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

  1. Remove necessary air filter tubing at throttle body.
  2.  
  3. Prior to removing an ignition coil (if necessary), spray compressed air around the coil base at cylinder head cover.
  4.  
  5. Prior to removing a spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber.
  6.  
  7. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert.
  8.  
  9. Inspect spark plug condition.
  10.  

To install:


WARNING
The 5.7L V8 is equipped with torque critical design spark plugs. Do not exceed 15 ft. lbs. (20 Nm) torque during installation. 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.

  1. Start the spark plug into cylinder head by hand to avoid cross threading aluminum threads. To aid in installation, attach an old spark plug boot or a piece of rubber hose to spark plug.
  2.  
  3. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots.
  4.  
  5. To prevent ignition crossfire, spark plug cables MUST be placed in cable tray (routing loom) into their original position.
  6.  
  7. Spark plug cables on the 5.7L engine are paired on cylinders 1 & 6, 2 & 3, 4 & 7 and 5 & 8. Before removing or disconnecting any spark plug cables, note their original position and 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. The cable retention clips must also be securely locked.

    Click image to see an enlarged view

    Fig. Spark Plug Cable Routing-2005 5.7L engine



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    Fig. Cable Routing Legend-2005 5.7L engine

  8.  
  9. Install ignition coil(s) to necessary spark plugs. Refer to Ignition Coil Installation.
  10.  
  11. Install spark plug cables to remaining spark plugs. Remember to apply dielectric grease to inside of boots.
  12.  
  13. Tighten spark plugs.
  14.  

 
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