Chrysler Full-Size Trucks 1989-1996 Repair Guide

Ignition Coil

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TESTING



See Figures 1, 2, 3, 4 and 5

The ignition coil should be tested with a special ignition coil tester, such as the Chrysler DRB scan tool, or equivalent. For basic function tests please refer to the "Checking For Spark'' test and the "Failure-To-Start Test.'' This procedure is to determine whether an operating coil may be below specification, or in some way faulty.



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Fig. Fig. 1: IGNITION COIL RESISTANCE

The ignition coil for the vehicles covered by this guide is in the following locations:



1989-92 engines: mounted to the firewall
 
1993-96 2.5L engines: mounted on the thermostat housing in front of the coolant temperature sensor
 
1993-96 V6 and V8 LDC engines: mounted to a bracket bolted to the right engine cylinder head
 
1993-96 5.9L HDC engines: mounted to a bracket bolted to the air injection pump (AIR pump) mounting bracket.
 



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Fig. Fig. 2: Ignition coil mounting-all 1989-92 models



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Fig. Fig. 3: Ignition coil wiring and mounting hardware-1993-96 2.5L engine

  1. Inspect the ignition coil for arcing while the engine is running. If the engine will not start, this can be performed while the engine is cranked by either an assistant or a remote starter. Look at the coil in dim or low light to aid visibility of any arcing.
  2.  



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Fig. Fig. 4: Ignition coil mounting-1993-96 3.9L and 5.2L/5.9L LDC engines

  1. Arcing at the tower will carbonize the wire boot, which, if it is connected to a new ignition coil, will cause the coil to fail. In such cases, clean all the carbonization away or replace the components as necessary.
  2.  



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Fig. Fig. 5: Ignition coil mounting-1993-96 5.9L HDC engine

  1. Using a coil tester or ohmmeter according to the manufacturer's instructions, test the primary and secondary resistance. Replace any coil that does not meet the specifications indicated in the accompanying chart.
  2.  
  3. Inspect the secondary coil wire for any sign of damage. Replace if any damage is found. Carbon tracking on the old wire can cause arcing and the failure of a new ignition coil.
  4.  

REMOVAL & INSTALLATION



1989-92 Models

See Figures 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the three wires from the coil. Mark them to identify for installation.
  4.  



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Fig. Fig. 6: Remove the coil bracket bolt at the cowl



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Fig. Fig. 7: Unscrew the coil mounting hardware, then remove the coil from the vehicle

  1. Unplug the condenser suppressor connector from the coil, if equipped.
  2.  
  3. Unbolt and remove the coil.
  4.  

To install:
  1. Bolt down the coil with old bolts.
  2.  
  3. Connect wires to coil making sure that the proper wires are connected where they should be.
  4.  
  5. Connect the condenser suppressor, if equipped.
  6.  
  7. Connect the battery negative cable.
  8.  

1993-96 Models

2.5L ENGINE
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the ignition secondary wire from the coil.
  4.  
  5. Unplug the engine harness connector from the coil.
  6.  
  7. Remove the ignition coil mounting screws. Remove the coil.
  8.  

To install:
  1. Install the ignition coil to the bracket on the cylinder block.
  2.  
  3. Plug in the engine harness connector. Connect the ignition coil wire.
  4.  
  5. Connect the negative battery cable.
  6.  

V6 AND V8 ENGINES
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the primary wiring from the ignition coil.
  4.  
  5. Disconnect the secondary spark plug wire from the coil.
  6.  
  7. Remove the two bolts and withdraw the coil from its mounting bracket.
  8.  

To install:
  1. Position the coil on its bracket and install the two bolts. Tighten them to 100 inch lbs. (11 Nm). If the bracket has been tapped for coil mounting bolts, these fasteners require less torque, so tighten them to 50 inch lbs. (5 Nm).
  2.  
  3. Connect all wiring to the ignition coil.
  4.  

 
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