Chrysler Caravan/Voyager/Town and Country 1996-1999

Spark Plug Wires

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TESTING



See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Checking individual plug wire resistance with a digital ohmmeter

At every tune-up/inspection, visually check the spark plug cables for burns cuts, or breaks in the insulation. Check the boots and the nipples on the distributor cap and/or coil. Replace any damaged wiring.

Every 50,000 miles (80,000 Km) or 60 months, the resistance of the wires should be checked with an ohmmeter. Wires with excessive resistance will cause misfiring, and may make the engine difficult to start in damp weather.

To check resistance, disconnect the spark plug wire from the plug and ignition coil or distributor, then use an ohmmeter to measure the resistance.

For 2.4L engines, the resistance should be as follows:



Cables #1 and #4: 4,200 ohms
 
Cables #2 and #3: 3,200 ohms
 

For 3.0L engines, the resistance should be as follows:



Cable #1: 14,000 ohms
 
Cable #2: 10,400 ohms
 
Cable #3: 14,900 ohms
 
Cable #4: 11,500 ohms
 
Cable #5: 17,500 ohms
 
Cable #6: 10,300 ohms
 
Coil lead: 11,100 ohms
 

For 3.3L and 3.8L engines, the resistance should be as follows:



Cable #1: 18,500 ohms
 
Cable #2: 15,500 ohms
 
Cable #3: 20,400 ohms
 
Cable #4: 21,200 ohms
 
Cable #5: 27,700 ohms
 
Cable #6: 26,700 ohms
 

If resistance falls outside of specifications, the cable(s) should be replaced with new ones.

REMOVAL & INSTALLATION



See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: If the wires are being removed, or at least disconnected from the distributor cap, always matchmark each wire to its correct terminal

As the spark plug wires must be routed and connected properly, if all of the wires must be disconnected from the spark plugs or from the ignition coil pack/distributor at the same time, be sure to tag

or mark the wires to assure proper reconnection.

When installing a new set of spark plug wires, replace the wires one at a time so there will be no mix-up. Start by replacing the longest cable first. Twist the boot of the spark plug wire 1 / 2 turn in each direction before pulling if off. Install the boot firmly over the spark plug. Route the wire exactly the same as the original. Insert the nipple firmly onto the tower on the ignition coil or distributor, if equipped. Be sure to apply silicone dielectric compound to the spark plug wire boots and tower connectors prior to installation.

For easier access, it may be necessary to remove the windshield wiper/motor module assembly from the vehicle. This will allow more room to work between the engine and the engine compartment firewall. Refer to Chassis Electrical for removal procedures.

 
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