Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Distributor

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Vehicles with the 2.0L, 2.4L and 2.7L engines are equipped with distributorless ignition systems.


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

Installation



2.5L Engine
Timing Disturbed
  1. Rotate the crankshaft until the No. 1 piston is at Top Dead Center (TDC) of the compression stroke.
  2.  
  3. Align the rotor with the distributor housing matchmark.
  4.  
  5. Install or connect the following:
    NOTE
    With the distributor fully seated, the rotor should align the No. 1 terminal of the distributor cap.



    Distributor
     



    Distributor hold-down nuts/washers and tighten the nuts to 108 inch lbs. (13 Nm)
     
    Spark plug cable bracket
     
    Both distributor wiring connectors
     
    Distributor cap
     
    Spark plug cables
     
    Transaxle dipstick tube
     

  6.  
  7. Install or connect the following, if removed:

    EGR tube and tighten the bolts to 95 inch lbs. (11 Nm)
     
    Air cleaner cover, resonator and inlet tube
     
    Throttle body hose clamp
     
    PCV hose
     
    Air cleaner housing cover clamps
     
    Air inlet resonator to intake manifold bolt
     
    Negative battery cable
     

  8.  

  1. Rotate the crankshaft until No. 1 piston is at Top Dead Center (TDC) of its compression stroke.
  2.  
  3. Rotate the rotor to the No. 1 terminal position on the distributor cap.
  4.  
  5. Lower the distributor into place, engaging the distributor drive with the drive on the camshaft. With the distributor fully seated on the engine, the rotor should be under the No. 1 terminal.
  6.  
  7. Install or connect the following:

    Distributor hold-down nuts and washers. Torque the nuts to 108 inch lbs. (13 Nm).
     
    Spark plug cable bracket
     
    Both distributor wiring connectors
     
    Distributor cap
     
    Spark plug cables
     
    Transaxle dipstick tube
     
    EGR tube. Torque the bolts to 95 inch lbs. (11 Nm).
     
    PCV hose
     
    Air cleaner
     
    Air inlet resonator
     
    Negative battery cable
     

  8.  

Timing Not Disturbed

NOTE
Before servicing the vehicle, refer to the Precautions section.

  1. Inspect the rotor for cracks or burned electrodes, and replace if defective. Install the rotor onto the distributor.
  2.  
  3. Inspect the O-ring seal. If nicked or cracked, replace with a new one. Be sure the O-ring is properly seated on the distributor.
  4.  
  5. Install or connect the following:
    NOTE
    When the distributor is installed properly, the rotor will be aligned with the previously made mark.



    Distributor drive with the slotted end of the camshaft
     



    Distributor hold-down nuts/washers and tighten to 108 inch lbs. (13 Nm)
     
    Spark plug cable bracket
     
    Both distributor wiring connectors
     
    Distributor cap
     
    Spark plug cables
     
    Transaxle dipstick tube
     
    EGR tube and tighten the bolts to 95 inch lbs. (11 Nm)
     
    Air cleaner cover, resonator and inlet tube
     
    Throttle body hose clamp
     
    PCV hose
     
    Air cleaner housing cover clamps
     
    Air inlet resonator to intake manifold bolt
     
    Negative battery cable
     

  6.  

  1. Inspect the rotor for cracks or a burned electrode. Replace if defective.
  2.  
  3. Install or connect the following:

    Rotor onto the distributor
     
    New O-ring on the distributor
     

  4.  
  5. Carefully, engage the distributor drive with the slotted end of the camshaft. When the distributor is installed properly, the rotor will be aligned with the previously made mark.
  6.  
  7. Verify proper rotor alignment with mark made at disassembly.
  8.  
  9. Install or connect the following:

    Distributor hold-down nuts and washers. Torque the nuts to 108 inch lbs. (13 Nm).
     
    Spark plug cable bracket
     
    Both distributor wiring connectors
     
    Distributor cap
     
    Spark plug cables
     
    Transaxle dipstick tube
     
    EGR tube. Torque the bolts to 95 inch lbs. (11 Nm).
     
    PCV hose
     
    Air cleaner
     
    Air inlet resonator
     
    Negative battery cable
     

  10.  

3.0L Engine
Engine Disturbed
  1. Rotate the crankshaft until the No. 1 piston is at Top Dead Center (TDC) of the compression stroke.
  2.  
  3. Align the rotor with the distributor housing matchmark.
  4.  
  5. Install or connect the following:
    NOTE
    With the distributor fully seated, the rotor should align the No. 1 terminal of the distributor cap.



    Distributor
     



    Distributor hold-down nuts/washers and tighten the nuts to 108 inch lbs. (13 Nm)
     
    Both distributor wiring connectors
     
    Distributor cap
     

  6.  
  7. Reinstall the intake manifold upper plenum with a new gasket and torque the bolts to 13 ft. lbs. (18 Nm) in a crisscross pattern.

    Spark plug cables
     
    Air cleaner housing cover with airflow sensor still attached
     
    Cold air intake duct
     
    Air intake hose with dangling resonator
     
    Battery
     

  8.  

Engine Not Disturbed

NOTE
Before servicing the vehicle, refer to the Precautions section.

  1. Inspect the rotor for cracks or burned electrodes, and replace if defective. Install the rotor onto the distributor.
  2.  
  3. Inspect the O-ring seal. If nicked or cracked, replace with a new one. Be sure the O-ring is properly seated on the distributor.
  4.  
  5. Install or connect the following:
    NOTE
    When the distributor is installed properly, the rotor will be aligned with the previously made mark.



    Distributor drive with the slotted end of the camshaft
     



    Distributor hold-down nuts/washers and tighten to 108 inch lbs. (13 Nm)
     
    Spark plug cable bracket
     
    Both distributor wiring connectors
     
    Distributor cap
     
    Spark plug cables
     

  6.  
  7. Reinstall the intake manifold upper plenum with a new gasket and torque the bolts to 13 ft. lbs. (18 Nm) in a crisscross pattern.

    Spark plug cables
     
    Air cleaner housing cover with airflow sensor still attached
     
    Cold air intake duct
     
    Air intake hose with dangling resonator
     
    Battery
     

  8.  

Removal & Installation



2.5L Engine

The 2.5L engine is equipped with a camshaft driven mechanical distributor with fixed ignition timing controlled by the Powertrain Control Module (PCM). The PCM determines spark advance. The Crankshaft Position (CKP) sensor and Camshaft Position (CMP) sensor are Hall effect devices. The CKP sensor is mounted remotely from the distributor, while the CMP sensor is mounted inside the distributor housing. Both sensors generate pulses that serve as inputs to the PCM; the PCM determines crankshaft position from these sensors, then calculates injector sequence and ignition timing, based on the data.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect, if necessary for access:

    Air inlet resonator to the intake manifold bolt
     
    Air cleaner cover to air cleaner housing cover clamps
     
    Positive Crankcase Ventilation (PCV) make-up air hose from the air inlet tube
     
    Throttle body hose clamp
     
    Air cleaner cover, resonator and inlet tube
     
    Exhaust Gas Recirculation (EGR) tube
     

  6.  
  7. Remove or disconnect the following:

    Spark plug wires from the distributor cap
     
    Distributor cap
     

  8.  
  9. Matchmark the rotor-to-distributor and the distributor-to-engine positioning to help with installation.

    Rotor
     
    Distributor-s 2 electrical harness connectors
     
    Distributor hold-down nuts and washers
     
    Spark plug cable mounting bracket, if necessary
     
    Transaxle dipstick tube
     
    Distributor

    Click image to see an enlarged view

    Fig. Prior to installation, align the distributor shaft with the distributor housing-2.5L and 3.0L engines

     

  10.  

The 2.5L engine is equipped with a camshaft driven mechanical distributor. This engine uses a fixed ignition timing system. The basic ignition timing is not adjustable. The Powertrain Control Module (PCM) determines spark advance. The Crankshaft Position (CKP) sensor and Camshaft Position (CMP) sensor are Hall Effect devices. The CKP sensor is mounted remotely from the distributor while the CMP sensor is mounted inside the distributor housing. Both sensors generate pulses that are inputs to the PCM. The PCM determines crankshaft position from these sensors. The PCM calculates injector sequence and ignition timing. There is a resistor built into the distributor cap. An ohmmeter connected between the center button and ignition coil terminal should read 5000 ohms.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.


    NOTE
    Mark the rotor position. A scribe mark indicates where to position the rotor when reinstalling the distributor.



    Negative battery cable from the left shock tower
     



    Air inlet resonator-to-intake manifold bolt
     
    Air cleaner cover-to-air cleaner housing clamp
     
    Positive Crankcase Ventilation (PCV) air hose from the air inlet tube
     
    Exhaust Gas Recirculation (EGR) tube
     
    Spark plug wires from the distributor cap
     
    Distributor cap
     



    Rotor
     
    Both electrical connectors from the distributor
     
    Distributor hold-down nuts and washers
     
    Spark plug cable mounting bracket
     
    Transaxle dipstick tube
     
    Distributor
     

  4.  

3.0L Engine

The 3.0L engine is equipped with a camshaft driven mechanical distributor with fixed ignition timing controlled by the Powertrain Control Module (PCM). The PCM determines spark advance. The Crankshaft Position (CKP) sensor and Camshaft Position (CMP) sensor are Hall effect devices. The CKP sensor is mounted remotely from the distributor, while the CMP sensor is mounted inside the distributor housing. Both sensors generate pulses that serve as inputs to the PCM; the PCM determines crankshaft position from these sensors, then calculates injector sequence and ignition timing, based on the data.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable first, and then remove the battery.
  4.  
  5. Remove or disconnect, if necessary for access:

    Air intake hose with dangling resonator
     
    Cold air intake duct
     
    Air cleaner housing cover with airflow sensor still attached
     

  6.  
  7. Air intake manifold upper plenum
  8.  
  9. Perform the following:

    Properly relieve the fuel pressure
     
    Drain the engine coolant
     

  10.  
  11. Remove the following electrical and sensor connectors:

    MAP sensor
     
    Power steering wire harness
     
    EGR regulator
     
    EVAP solenoid
     
    Knock sensor
     
    Crankshaft position sensor
     
    Heated oxygen sensor (right bank)
     
    Fuel injectors
     
    Distributor
     
    Fuel injector harness
     

  12.  
  13. Also remove the following vacuum lines:

    EGR vacuum regulator valve
     
    Vacuum hoses to throttle body
     
    Brake booster vacuum hose
     

  14.  
  15. Remove the following hardware:

    EGR valve and pipe
     
    Power steering pump drivebelt
     
    Power steering pump stay
     
    Intake manifold stay (front and rear)
     
    Engine mount stay
     
    Upper portion of the plenum and gasket
     

  16.  
  17. Continue removing the distributor by removing the following:
    NOTE
    The cables and cap are numbered with their corresponding cylinder numbers



    Spark plug cables
     



    Distributor from engine

    Click image to see an enlarged view

    Fig. Prior to installation, align the distributor shaft with the distributor housing-2.5L and 3.0L engines



    Click image to see an enlarged view

    Fig. Location of distributor-3.0L engine



    Click image to see an enlarged view

    Fig. Electrical connectors-3.0L engine



    Click image to see an enlarged view

    Fig. Upper plenum and small parts exploded diagram-3.0L engine

     

  18.  

 
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