CTS 2003-2005

Ignition Coil

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Removal & Installation



2.8L & 3.6L Engines
  1. Turn the ignition OFF .
  2.  
  3. Remove the engine appearance cover.
  4.  
  5. Disconnect the air cleaner duct from the throttle body. Disconnect the positive crankcase ventilation (PCV) hose from the camshaft cover. Remove the intake manifold bolts, but do not separate the upper intake manifold from the lower intake manifold.
  6.  
  7. Remove the intake manifold brace bolts and the brace.
  8.  
  9. Remove and reposition the upper intake manifold with the lower intake manifold in order to gain sufficient clearance for ignition coil removal.
  10.  
  11. Remove the ignition coil electrical connector.
  12.  
  13. Remove the ignition coil bolt.
  14.  
  15. Remove the ignition coil(s).
  16.  

To install:

  1. Install the ignition coil(s).
  2.  
  3. Install the ignition coil bolt(s) and tighten to 89 inch lbs. (10 Nm).
  4.  
  5. Install the ignition coil electrical connector(s).
  6.  
  7. Install the intake manifold.
  8.  
  9. Install the engine cover.
  10.  

3.2L Engine
Bank 1
  1. Turn the ignition OFF .
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the fuel return pipe and feed pipe from the fuel rail.
  6.  
  7. Disconnect the EVAP quick connect fitting.
  8.  
  9. Open the retainer located at the engine control module (ECM) bracket in order to remove the chassis hose/pipes.
  10.  
  11. Disconnect the 2 cable harness clips securing the engine wiring harness to the ECM bracket.
  12.  
  13. Remove the 2 bolts securing the afterboil coolant pump to the ECM bracket, and position aside.
  14.  
  15. Remove the screw securing the engine control module (ECM) ground wire to the ECM.
  16.  
  17. Flip the release levers to the open position and disconnect the ECM connectors from the ECM.
  18.  
  19. Remove the bolt securing the coolant inlet pipe to the ECM bracket.
  20.  
  21. Remove the ECM bracket bolts from the intake plenum and cylinder head.
  22.  
  23. Remove the ECM bracket from the engine with the ECM still attached, and position aside.
  24.  
  25. Disconnect the electrical connector from the right knock sensor pigtail.
  26.  
  27. Disconnect the electrical connector from the coil pack.
  28.  
  29. Remove the coil pack retainer bolts.
  30.  
  31. Thread Coil Pack Remover J-43301into the coil pack.
  32.  
  33. With even pressure, lift and remove the coil pack from the cam cover.
  34.  

To install:

  1. Inspect the coil pack seals and spark plug boots for damage or wear. Replace as necessary.
  2.  
  3. Align the spark plug boots with the spark plugs.
  4.  
  5. Carefully press and seat the coil pack in place.
  6.  
  7. Install the coil pack retainer bolts and tighten to 71 inch lbs. (8 Nm).
  8.  
  9. Connect the electrical connector to the coil pack.
  10.  
  11. Connect the electrical connector to the right knock sensor pigtail.
  12.  
  13. Position the ECM and bracket to the engine.
  14.  
  15. Install the ECM bracket bolts to the cylinder head and intake plenum.
  16.  
  17. Tighten the ECM-to-cylinder head bolts to 15 ft. lbs. (20 Nm).
  18.  
  19. Tighten the ECM-to-intake plenum bolts to 71 inch lbs. (8 Nm).
  20.  
  21. Install the bolt securing the coolant inlet pipe to the ECM bracket and tighten to 15 ft. lbs. (20 Nm).
  22.  
  23. Carefully align the harness connectors with the ECM connectors.
  24.  
  25. Guide the connectors into place while moving the release levers to the locked position.
  26.  
  27. Install the screw securing the ECM ground wire to the ECM.
  28.  
  29. Install the 2 bolts securing the afterboil coolant pump to the ECM bracket and tighten to 89 inch lbs. (10 Nm).
  30.  
  31. Connect the 2 cable harness clips securing the engine wiring harness to the ECM bracket.
  32.  
  33. Insert the chassis hose/pipes into the retainer located at the ECM bracket.
  34.  
  35. Close the retainer.
  36.  
  37. Connect the EVAP quick connect fitting.
  38.  
  39. Connect the fuel return pipe and feed pipe to the fuel rail.
  40.  

Bank 2
  1. Turn the ignition OFF .
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the oil filler spout by unlocking the tab and twisting counterclockwise.
  6.  
  7. Disconnect the brake booster vacuum hose and wiring harness from the remote power steering fluid reservoir.
  8.  
  9. Disconnect the vacuum brake booster hose from the vacuum source.
  10.  
  11. Remove the remote power steering fluid reservoir mounting bolts, and position aside.
  12.  
  13. Disconnect the electrical connector from the coil pack.
  14.  
  15. Remove the coil pack retainer bolts.
  16.  
  17. Thread Coil Pack Remover J-43301into the coil pack.
  18.  
  19. With even pressure, lift and remove the coil pack from the cam cover.
  20.  

To install:

  1. Inspect the coil pack seals and spark plug boots for damage or wear. Replace as necessary.
  2.  
  3. Align the spark plug boots with the spark plugs.
  4.  
  5. Carefully press and seat the coil pack in place.
  6.  
  7. Install the coil pack retainer bolts and tighten to 71 inch lbs. (8 Nm).
  8.  
  9. Connect the electrical connector to the coil pack.
  10.  
  11. Install the remote power steering fluid reservoir.
  12.  
  13. Connect the vacuum brake booster hose to the vacuum source.
  14.  
  15. Connect the brake booster vacuum hose and wiring harness to the remote power steering fluid reservoir.
  16.  
  17. Install the oil filler spout.
  18.  

3.5L (VIN H) Engine

NOTE
The 2000 Intrigue with the 3.5L (VIN H) engine has a direct-mount coil ignition system and uses no spark plug wires.



Click image to see an enlarged view

Fig. Remove the engine acoustic/cosmetic cover, the seven bolts, then carefully remove the ignition coil "cassette"-3.5L (VIN H) engine

  1. Verify that the ignition switch is in the OFF position.
  2.  
  3. Remove the engine cosmetic/acoustic shield (technically called the injector sight shield). Remove the two mounting nuts and then lift the cover off the mounting studs by lifting at the front of the cover.
  4.  
  5. Unplug the ignition coil module electrical connector.
  6.  
  7. Remove the seven ignition coil assembly (GM calls it the 'ignition cassette') to cam cover mounting bolts.
  8.  
  9. Gently pry the cassette away from the cam cover using a screwdriver (protect the 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.
  10.  
  11. On some vehicles, the oil level indicator (dipstick) tube may interfere with the removal of the front bank coil cassette. Remove the oil level indicator tube retaining bolt and move the oil tube, as necessary.
  12.  
  13. Lift the coil cassette straight up off of the spark plugs.
  14.  
  15. Remove the secondary boots from the spark plugs or the ignition coils, using a twisting motion to break the seal. Use tool J 43094 Spark Plug Boot Removal Tool or its equivalent. This is a long, padded gripping tool designed to reach down into the spark plug well to remove the boots. GM cautions against the use of pliers, screwdrivers or any unauthorized tool to remove the boots.
  16.  

To install:

  1. Do not re-install any component that has visible signs of damage. Check the boots for a missing or damaged internal spring. Make sure the boots are installed right side up. Make sure the ignition cassette to cam cover ground spring is in places. If necessary, repair a torn perimeter seal with RTV sealant. Clean all mounting surfaces before re-installing components.
  2.  
  3. Install the boots onto the ignition coils (until bottomed out).
  4.  
  5. Install the cassette assembly straight down onto the spark plug boots. 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 coil assembly as straight down onto the plugs as possible.
  6.  
  7. Install the seven ignition cassette to cam cover mounting bolts and tighten to 84 inch lbs. (9.5 Nm).
  8.  
  9. Plug in the ignition control module electrical connector.
  10.  
  11. If the oil level indicator tube was moved during disassembly, move the tube back into position, then install the retaining bolt and tighten to 80 inch lbs. (9 Nm).
  12.  
  13. Keeping the engine cosmetic/acoustic cover as level as possible, place the rear of the shield under the mounting bracket, and align and press the cover onto the mounting studs. Install the nuts and snug down to just 27 inch lbs. (3 Nm).
  14.  

5.7L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel injector sight shield.
    NOTE
    The ignition coils can be removed individually or as an assembly, depending on the repair being performed.

  4.  
  5. If replacing an individual coil, disconnect the wire harness at the coil. If removing the coil assembly, disconnect the main coil harness connector.
  6.  
  7. Disconnect the spark plug wire at the ignition coils.
  8.  
  9. If replacing an individual coil, remove the ignition coil mounting bolts and/or nut that retains the coil to the coil bracket.
  10.  
  11. If removing the coil assembly, remove the bolts securing the coil bracket to the valve rocker arm cover.
  12.  
  13. Remove the ignition coil or coil assembly.
  14.  

To install:

  1. Install the ignition coil or coil assembly.
  2.  
  3. Install the ignition coil bolts and/or nuts.
  4.  
  5. Tighten the coil to bracket bolts/nuts to 106 inch lbs. (12 Nm).
  6.  
  7. Tighten the coil to bracket-to-valve cover bolts/nuts to 106 inch lbs. (12 Nm).
  8.  
  9. Connect the spark plug wires at the ignition coils.
  10.  
  11. Connect the individual ignition coil or main coil harness connector.
  12.  
  13. Install the fuel injector sight shield.
  14.  
  15. Connect the negative battery cable
  16.  

Except 3.5L (VIN H) Engine


Click image to see an enlarged view

Fig. Tag and detach the connectors, unfasten the retaining bolts, then remove the coil and module assembly from the vehicle



Click image to see an enlarged view

Fig. The ignition coils are secured to the module with retaining bolts/screws-3.4L shown



Click image to see an enlarged view

Fig. The ignition coils are secured to the Ignition Control Module (ICM) with retaining screws



Click image to see an enlarged view

Fig. Ignition control module/coil assembly mounting

5L engine, similar ignition systems. The ignition coil removal procedures are similar, differing only in the types of wiring connections.

  1. Disconnect the negative battery cable.
  2.  
  3. Note the position of the spark plug wires for installation. Numbered tags of masking tape or other identification will save time at installation. Spark plug wires MUST be returned to their original and proper locations. Unplug the spark plug wires from the ignition coils.
  4.  
  5. Remove the 2 screws securing the each ignition coil to the ignition control module and remove the ignition coil(s).
  6.  

To install:

  1. Position the ignition coil(s) to the ignition control module.
  2.  
  3. Install the 2 retaining screws for each coil, then tighten to 40 inch lbs. (5 Nm).
  4.  
  5. Attach the spark plugs wires as noted during removal.
  6.  
  7. Connect the negative battery cable.
  8.  

Testing



Except 3.5L (VIN H) Engine
  1. Remove the ignition coil(s).
  2.  
  3. Using an ohmmeter, check the resistance between the primary terminals on the underside of the coil. The resistance should be 0.50-0.90 ohms.
  4.  
  5. Check the resistance between the secondary terminals. It should be 5,000-8,000 ohms.
  6.  
  7. If the coil failed either test, replace the coil.
  8.  

 
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