Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Spark Plugs

Print

Inspection



Check the plugs for deposits and wear. If they are not going to be replaced, clean the plugs thoroughly. Remember that any kind of deposit will decrease the efficiency of the plug. Plugs can be cleaned on a spark plug cleaning machine, which can sometimes be found in service stations, or you can do an acceptable job of cleaning with a stiff brush. If the plugs are cleaned, the electrodes must be filed flat. Use an ignition points file, not an emery board or the like, which will leave deposits. The electrodes must be filed perfectly flat with sharp edges; rounded edges reduce the spark plug voltage by as much as 50 percent.

Check the spark plug gap before installation. The ground electrode (the L-shaped one connected to the body of the plug) must be parallel to the center electrode and the specified size wire gauge (please refer to the Tune-Up Specifications chart for details) must pass between the electrodes with a slight drag.


NOTE
NEVER adjust the gap on a used platinum type spark plug.

Always check the gap on new plugs as they are not always set correctly at the factory. Do not use a flat feeler gauge when measuring the gap on a used plug, because the reading may be inaccurate. A round-wire type gapping tool is the best way to check the gap. The correct gauge should pass through the electrode gap with a slight drag. If you're in doubt, try one size smaller and one larger. The smaller gauge should go through easily, while the larger one shouldn't go through at all. Wire gapping tools usually have a bending tool attached. Use that to adjust the side electrode until the proper distance is obtained. Absolutely never attempt to bend the center electrode. Also, be careful not to bend the side electrode too far or too often as it may weaken and break off within the engine, requiring removal of the cylinder head to retrieve it.

Click image to see an enlarged view

Fig. "a1p40"" Inspect the spark plug to determine engine running conditions



Click image to see an enlarged view

Fig. "S212"" A variety of tools and gauges are needed for spark plug service



Click image to see an enlarged view

Fig. "S903"" Checking the spark plug gap with a feeler gauge



Click image to see an enlarged view

Fig. "S904"" Adjusting the spark plug gap



Click image to see an enlarged view

Fig. "S141"" If the standard plug is in good condition, the electrode may be filed flat-WARNING: do not file platinum plugs

Inspection & Gapping



All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1,000-volt spark plug tester.


NOTE
Do not use an ohmmeter to check the resistance of the spark plugs. This will give an inaccurate reading.

Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder.

Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. After cleaning, file the center electrode flat with a small flat point file or jewelers file. Adjust the gap between the electrodes Setting Spark Plug Electrode Gap to the dimensions specified in the chart at the end of this section.

Special care should be used when installing spark plugs in the 2.0/2.4L cylinder head spark plug wells. Be sure the plugs do not drop into the wells or damage to the electrodes can occur.

Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Overtightening can also damage the cylinder head.

Removal & Installation



The ignition coil assembly for the 4 cylinder engines consists of 2 independent coils molded together. The coil assembly for the 4 cylinder engines is mounted on the cylinder head cover. Spark plug cables route to each cylinder from the coil. The coil assemblies for the 2.7L are mounted on the head cover. It is a coil on plug assembly and each cylinder has an ignition coil assembly.

2.0L & 2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    Inspect the spark plug condition.



    Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1 / 2 turn and pulling straight up in a steady motion.
     
    Remove the spark plug using a spark plug socket with a rubber or foam insert.
     



    The new plugs should be checked for the proper gap. The gap should be 0.033-0.038 inch (0.838-0.965mm) on 2.0L engines or 0.039-0.043 inch (1.0-1.1mm) on 2.4L engines.

    Click image to see an enlarged view

    Fig. Spark plug adjustment-2.0L and 2.4L engines

     

  2.  

To install:


NOTE
To avoid cross threading, start the spark plug into the cylinder head by hand.



Install the spark plugs and torque to 20 ft. lbs. (28 Nm)
 
Install spark plug insulators over spark plugs.
 
Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.
 
Install spark plug cable to coil.
 

2.4L Engine
  1. Disconnect the spark plug wires from the spark plug.
  2.  
  3. Use a spark plug socket and wrench to remove the spark plugs.
  4.  
  5. To install, reverse the removal procedure. Tighten the spark plugs to 13 ft. lbs. (18 Nm).
  6.  

2.5L & 3.0L Engines

If gap adjustment is required of platinum plug, bend only the ground electrode. Do not touch the platinum electrode. Use only a proper gapping tool and check with a taper gap gauge


WARNING
Iridium plugs are used on 3.0L engine. Use care not to damage the iridium tips of the iridium plugs as they are very delicate. Do not attempt to adjust the gap on these plugs.


WARNING
Do not apply anti-seize compound to new spark plugs.

Cylinder #1, #3 Or #5
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative cable from auxiliary jumper terminal.
     
    Unplug connectors from MAP and intake air temperature sensors
     
    Plenum support bracket bolt located rearward of MAP sensor
     
    Bolt holding air inlet resonator to intake plenum
     
    Throttle body air inlet hose clamp.
     
    Snaps holding air cleaner housing cover to housing.
     
    Air cleaner cover and inlet hoses from engine.
     
    TPS and idle air control motor connectors
     

  4.  
  5. Pry retainer tab back on throttle cable and slide cable out of bracket
  6.  
  7. Slide speed control cable out of bracket, if equipped
  8.  
  9. Remove EGR tube from intake plenum EGR
  10.  
  11. Remove plenum support bracket bolt located rearward of EGR tube
  12.  
  13. Remove bolts holding upper intake plenum and remove plenum.
    NOTE
    Always remove the ignition cable by grasping at the spark plug boot turning, the boot 1 / 2 turn and pulling straight back in a steady motion.

  14.  
  15. Prior to removing the spark plug, clear the area of debris by spraying compressed air around the spark plug hole and the area around the spark plug.

    Remove the spark plug using a spark plug socket with a rubber or foam insert.
     
    Inspect the spark plug condition.

    Click image to see an enlarged view

    Fig. Spark plug adjustment-2.5L and 3.0L engines

     

  16.  

To install:

  1. To avoid cross threading, start the spark plug into the cylinder head by hand and torque to 20 ft. lbs. (28 Nm)

    Ignition cables over spark plugs.
     
    Upper intake plenum with a new gasket and torque the bolts to 13 ft. lbs. (18 Nm)
     
    Bolts at plenum support brackets and torque to 13 ft. lbs. (18 Nm)
     
    EGR tube to plenum and torque the screws to 95 inch lbs. (11 Nm)
     
    Throttle and speed control cables, if equipped.
     

  2.  
  3. Attach electrical connectors to sensors.
  4.  
  5. Tighten air inlet tube clamps
  6.  
  7. Connect negative terminal to auxiliary jumper terminal.
  8.  

Cylinder #2, #4 Or #6
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Ignition cable by grasping at the spark plug boot turning, the boot 1 / 2 turn and pulling straight back in a steady motion.
     
    Clear debris from the spark plug hole by spraying compressed air around the spark plug hole and the area around the spark plug.
     
    Spark plug using a spark plug socket with a rubber or foam insert.
     

  4.  
  5. Inspect the spark plug condition.

    Click image to see an enlarged view

    Fig. Spark plug adjustment-2.5L and 3.0L engines

  6.  

To install:

  1. To avoid cross threading, start the spark plug into the cylinder head by hand.

    Torque spark plugs to 20 ft. lbs. (28 Nm)
     
    Install ignition cables over spark plugs.
     

  2.  

2.7L Engine
  1. Remove the ignition coils. Refer to Ignition Coil, removal and installation.
  2.  
  3. Use a spark plug socket and wrench to remove the spark plugs.
  4.  
  5. To install, reverse the removal procedure. Tighten the spark plugs to 15 ft. lbs. (20 Nm).
  6.  

 
label.common.footer.alt.autozoneLogo