GM Malibu/Cutlass 1997-2000

Ignition Coil(s)

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TESTING



2.4L Engine
  1. Remove the Ignition Control Module (ICM) and ignition coil as an assembly; refer to the procedure in this section.
  2.  
  3. Separate the electronic ICM housing assembly from the ignition coils.
  4.  
  5. Remove the Ignition Coils.
  6.  
  7. Before testing, visually inspect the surface of the ignition coils for carbon paths or cracking which will contribute to weak spark symptoms.
  8.  
  9. Using an ohmmeter, check the resistance between the secondary terminals, where the spark connect boots connect, one coil at a time. Resistance should be 10,000 ohms or higher.
  10.  
  11. If the coil secondary resistance is less than 10,000 ohms, the coil must be replaced.
  12.  

3.1L Engine
  1. Tag and disconnect the two plug wires attached to the suspected coil.
  2.  
  3. Remove the two screws securing the ignition coil to the Ignition Control Module (ICM).
  4.  
  5. Remove the ignition coil.
  6.  
  7. Before testing, visually inspect the coil for carbon paths or cracks which will contribute to weak spark symptoms.
  8.  
  9. 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.
  10.  
  11. Check the resistance between the secondary terminals. It should be 5,000-8,000 ohms.
  12.  
  13. If the coil failed either test, it must be replaced.
  14.  

REMOVAL & INSTALLATION



2.4L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Detach the Ignition Control Module (ICM) harness connector.
  4.  
  5. Remove the accelerator and cruise control cables from the hold-down clip.
  6.  
  7. Remove the fuel line retainer clip bolt.
  8.  



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Fig. Exploded view of the ignition coil and ICM on the 2.4L engine. Note the location of the contact springs between the housing and spark plug boots



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Fig. Detach the harness connector, which is located at the end of the ignition component cover

  1. Remove the four ICM cover bolts.
  2.  



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Fig. The ICM cover is secured with four retaining bolts


NOTE
Be sure to check each boot for the spring, located inside the boot. If any springs are missing, replace before reinstalling.

  1. Gently lift the ICM cover up off of the spark plugs. Some boots and retainers may pull off of the ignition coil housing, this is not unusual, simply replace them during installation.
  2.  


NOTE
If the boots stick to the spark plugs, using a spark plug boot remover tool or soft-jawed pliers, remove by first twisting, then carefully pulling upward on the retainers. Reinstall the boots and retainers on the ignition coil housing secondary terminals. The boots and retainers must be in place on the ignition coil housing prior to installation or damage to the ignition system could result.



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Fig. The spark plug boots and retainers may pull off of the housing assembly. Simply replace before installation

  1. Remove the housing-to-cover screws.
  2.  


NOTE
When removing the housing from the cover screws, make sure the ground strap stays in place.



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Fig. Remove the ignition coil housing-to-cover screws



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Fig. Disconnect the ICM harness connector after separating the coils from the module

  1. Separate the Ignition Control Module (ICM) housing assembly from the ignition coils.
  2.  
  3. Detach the ICM harness connector from the ignition coils.
  4.  
  5. Unplug the electrical connector from the ignition coil.
  6.  



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Fig. This connector is to be disengaged if the coils are to be separated

  1. Remove the contact springs from the housing.
  2.  
  3. Remove the ignition coil seals from the coils.
  4.  



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Fig. The contact springs are replaced when a new coil is installed. Make sure new contact springs come with the coil



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Fig. The coil seals are removed for testing and inspection

To install:

  1. Install the ignition coil seals to the coils.
  2.  
  3. Install the contact springs to the housing.
  4.  
  5. Connect the ignition coils to the ICM wiring harness.
  6.  
  7. Gently place the ignition coils into the housing assembly.
  8.  


NOTE
When installing the housing, make sure the ground strap is in place.



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Fig. The ground strap must be in place before the housing bolts are installed and tightened

  1. Fasten the housing bolts and tighten to 35 inch lbs. (4 Nm).
  2.  
  3. Connect the spark plug boots and retainers to the housing.
  4.  
  5. Install the assembly to the engine, while carefully aligning the spark plugs to the spark plug boots.
  6.  


WARNING
The cover bolts must be installed with the rubber side of the isolator washers facing down.

  1. Coat the threads of the retaining bolts with a suitable thread sealant. Install the retaining bolts, then tighten to 16 ft. lbs. (22 Nm).
  2.  



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Fig. Make sure the rubber side of the isolator washers face down during installation

  1. Install the fuel line retainer clip bolt.
  2.  
  3. Install the accelerator and cruise control cables into the hold-down clip.
  4.  
  5. Attach the ICM 11-pin harness electrical connector.
  6.  
  7. Connect the negative battery cable.
  8.  

3.1L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Tag and detach the two spark plug wires connected to the coil you are removing.
  4.  
  5. If necessary, detach the coil and module assembly from it's mounting bracket. Follow the procedure under Ignition Control Module (ICM) removal.
  6.  



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Fig. Each ignition coil is held to the module with two retaining screws

  1. Remove the two screws securing the ignition coil to the Ignition Control Module (ICM).
  2.  
  3. Remove the ignition coil.
  4.  

To install:

  1. Align the terminals under the coil with the plug on the ICM. Firmly press the coil onto the ICM.
  2.  
  3. Install the two screws holding coil to the ICM and tighten to 40 inch lbs. (4 Nm)
  4.  
  5. Attach the two spark plug wires that were disconnected during removal.
  6.  
  7. Connect the negative battery cable.
  8.  

 
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