Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Distributor Cap & Rotor

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Inspection



2.5L And 3.0L Engines

There is a resistor built into the distributor cap. Connect an ohmmeter between the center button and ignition coil terminal. Ohmmeter should read 5000 ohms. Inspect rotor for cracks, burning and pitting and replace if necessary.

Click image to see an enlarged view

Fig. Distributor cap-2.5L and 3.0L Engines

Removal & Installation




CAUTION
The ignition system generates approximately 32,000 volts. Personal injury could result from contact with this system.

  1. Remove the bolt holding air inlet resonator to intake manifold.
  2.  
  3. Loosen clamps holding air cleaner cover to air cleaner housing.
  4.  
  5. Remove the PCV make-up air hose from air inlet tube.
  6.  
  7. Loosen hose clamp at throttle body.
  8.  
  9. Remove the air inlet tube, resonator and air cleaner cover.
  10.  
  11. Remove the EGR tube.
  12.  
  13. Remove the spark plug cables from distributor cap.
  14.  
  15. Loosen distributor cap hold down screws and remove cap.
  16.  
  17. Transfer cables from old cap to new cap. The cap is numbered and so are the cables.
  18.  

To install:

  1. Install the distributor cap.
  2.  
  3. Install the distributor hold down washers and nuts. Tighten nuts to 9 ft. lbs. (13 Nm)
  4.  
  5. Install the EGR tube.
  6.  
  7. Install the air inlet tube, resonator and air cleaner cover.
  8.  
  9. Tighten hose clamp at throttle body.
  10.  
  11. Install the PCV make-up air hose from air inlet tube.
  12.  
  13. Tighten clamps holding air cleaner cover to air cleaner housing.
  14.  
  15. Install the bolt holding air inlet resonator to intake manifold.
  16.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Bolt holding air inlet resonator to intake manifold.
     
    Clamps holding air cleaner cover to air cleaner housing.
     
    PCV make-up air hose from air inlet tube.
     
    Hose clamp at throttle body.
     
    Air inlet tube, resonator and air cleaner cover.
     
    EGR tube.
     
    Spark plug cables from distributor cap.
     

  4.  
  5. Loosen distributor cap hold down screws and remove cap
    NOTE
    The rotor is friction-fitted to the distributor shaft and can be pulled straight off.

  6.  
  7. Transfer cables from old cap to new cap. The cap and cables are numbered with their corresponding cylinder numbers.
  8.  

To install:

Click image to see an enlarged view

Fig. Distributor cap-2.5L and 3.0L Engines

  1. Install or connect the following:

    Distributor cap.
     
    Distributor holddown washers and nuts and torque to 9 ft. lbs (13 Nm)
     
    EGR tube.
     
    Air inlet tube, resonator and air cleaner cover.
     
    Hose clamp at throttle body.
     
    PCV make-up air hose from air inlet tube.
     
    Clamps holding air cleaner cover to air cleaner housing and securely tighten.
     
    Bolt holding air inlet resonator to intake manifold and securely tighten.
     

  2.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Air cleaner
     
    Spark plug cables from distributor cap.
     

  4.  
  5. Loosen distributor cap hold down screws and remove cap
    NOTE
    The rotor is friction-fitted to the distributor shaft and can be pulled straight off.

  6.  
  7. Transfer cables from old cap to new cap. The cap and cables are numbered with their corresponding cylinder numbers.
  8.  

To install:

Click image to see an enlarged view

Fig. Distributor cap-2.5L and 3.0L Engines

  1. Install or connect the following:
    NOTE
    Make sure the new cap has an O-ring in its base.



    Distributor rotor
     
    Distributor cap
     



    Distributor holddown washers and nuts and torque to 20 inch lbs. (2.3 Nm)
     
    Air cleaner
     

  2.  

Testing



There is a resistor built into the distributor cap. Connect an ohmmeter between the center button and ignition coil terminal. Ohmmeter should read 5000 ohms.

 
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