Aurora 2001-2003

Ignition Coil

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.

  4.  
  5. Remove the mounting nuts retaining the injector sight shield.
  6.  
  7. Lift the injector sight shield off the mounting studs by lifting at the front of the cover.
  8.  
  9. Disconnect the electrical connector from the ignition control module.
  10.  
  11. Remove the 7 bolts retaining the ignition cassette to the cam cover.
  12.  
  13. Gently pry the cassette away from the cam cover using a screwdriver.
    NOTE
    Protect finished surfaces from scratches with a shop cloth. Pry a small amount in several locations around the edge of the cassette in order to lift the assembly as evenly as possible. DO NOT insert the screwdriver far enough to tear the perimeter seal on the cassette.


    NOTE
    On some vehicles the oil level indicator tube may interfere with the removal of the front bank coil cassette. Remove the bolt retaining the oil level indicator tube and move the oil level indicator tube if necessary.

  14.  
  15. Lift the cassette straight up off the spark plugs.
  16.  
  17. Remove the secondary boots from the spark plugs or the ignition coils using a twisting motion to break the seal.
  18.  
  19. Remove the cover from the ignition coils.
  20.  
  21. Remove the ignition control module retaining screws.
  22.  
  23. Remove the ignition control module (ICM).

    Click image to see an enlarged view

    Fig. Injector sight shield

  24.  

To install:

  1. Install the ignition control module on the ignition coils.
  2.  
  3. Install the ignition control module retaining screws and tighten to 10 inch lbs. (1.1 Nm)
  4.  
  5. Install the cover on the ignition coils.
  6.  
  7. Install the boots on the ignition coils until the boots bottom out.
  8.  
  9. Install the cassette assembly straight down onto the spark plugs. If this is not possible due to space limitations, rear bank, just-start the boots onto the spark plugs and then align and start the ignition coil towers into the boots. Press the ignition cassette down on the plugs as straight as possible.
  10.  
  11. Install the 7 bolts that retain the ignition coil cassette to the cam cover and tighten the bolts to 84 inch lbs. (10 Nm)
  12.  
  13. Connect the electrical connector to the ignition control module.
  14.  
  15. If the oil level indicator tube was moved during disassembly, move the tube back into position and install the retaining bolt and tighten the bolt to 80 inch lbs. (9 Nm)
  16.  
  17. Keeping the injector sight shield as level as possible, place the rear of the shield under the mounting bracket.
  18.  
  19. Align and press the injector sight shield onto the mounting studs.
  20.  
  21. Install the mounting nuts onto the mounting studs and tighten to 27 inch lbs. (3 Nm)
  22.  
  23. Reconnect the negative battery cable and reinstall the rear seat cushion.
  24.  

4.0L Engine
Front Bank
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.

  4.  
  5. Remove the fuel injector sight shield.
  6.  
  7. Disconnect the ignition control module electrical connector.
  8.  
  9. Disconnect the AIR vacuum control solenoid valve electrical connector.
  10.  
  11. Remove the AIR shut-off valve.
  12.  
  13. Using the removal sequence (1, 2, 3, 4, 5, 6, 7, 8) , remove the ignition cassette retaining bolts.
  14.  
  15. Carefully remove the ignition cassette.

    Click image to see an enlarged view

    Fig. Ignition cassette bolt tightening sequence.

  16.  

To install:


NOTE
Ensure the ignition cassette grounding spring and the insulator are in place when installing the ignition cassette.

  1. Connect the spark plug boots to the spark plugs.
  2.  
  3. Carefully install the ignition cassette.
  4.  
  5. Install the ignition cassette retaining bolts using the installation torque sequence (1, 2, 3, 4, 5, 6, 7, 8), tighten the ignition cassette retaining bolts to 80 inch lbs. (9 Nm)
  6.  
  7. Install the AIR shut-off valve.
  8.  
  9. Reconnect the AIR vacuum control solenoid valve electrical connector.
  10.  
  11. Reconnect the ignition cassette electrical connector.
  12.  
  13. Install the fuel injector sight shield.
  14.  

Rear Bank
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
    NOTE
    Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.


    NOTE
    The battery is located beneath the rear seat cushion.

  4.  
  5. Remove the fuel injector sight shield.
  6.  
  7. Disconnect the ignition control module electrical connector.
  8.  
  9. Using the removal sequence (1, 2, 3, 4, 5, 6, 7, 8), remove the ignition cassette retaining bolts.
  10.  
  11. Carefully remove the ignition cassette.

    Click image to see an enlarged view

    Fig. Ignition cassette bolt tightening sequence.

  12.  

To install:


NOTE
Be sure the ignition cassette grounding spring and insulator are in place when installing the ignition cassette.

  1. Connect the spark plug boots to the spark plugs.
  2.  
  3. Carefully install the ignition cassette.
  4.  
  5. Install the ignition cassette retaining bolts and using the installation torque sequence (1, 2, 3, 4, 5, 6, 7, 8), tighten the ignition cassette retaining bolts to 80 inch lbs. (9 Nm)
  6.  
  7. Reconnect the ignition cassette electrical connector.
  8.  
  9. Install the fuel injector sight shield.
  10.  
  11. Reconnect the negative battery cable and reinstall the rear seat cushion.
  12.  

 
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