Engine system DODGE RAM 2003 Service Repair Manual

(6) If equipped with dual battery system (certain
diesel equipped models), connect positive lead of volt-
meter to positive battery cable clamp on battery
located on left side of vehicle. Connect negative lead
of voltmeter to positive battery terminal post on bat-
tery located on right side of vehicle. Rotate and hold
ignition switch in Start position. Observe voltmeter.If reading is above 0.2 volt, clean and tighten battery
cables at both batteries. Repeat test. If reading is
still above 0.2 volt, replace faulty positive battery
cable.
If resistance tests detect no feed circuit problems,
refer toStarter Motorin the Diagnosis and Testing.
CONTROL CIRCUIT TESTING
The starter control circuit components should be
tested in the order in which they are listed, as fol-
lows:
²Starter Relay- Refer toStarter RelayDiag-
nosis and Testing.
²Starter Solenoid- Refer toStarter Motor
Diagnosis and Testing.
²Ignition Switch- Refer toIgnition Switch
and Key Lock Cylinder
²Clutch Pedal Position Switch- If equipped
with manual transmission, refer toClutch Pedal
Position Switchin 6, Clutch.
²Park/Neutral Position Switch- If equipped
with automatic transmission, refer toPark/Neutral
Position Switchin 21, Transmission.
²Wire harnesses and connections- Refer to 8,
Wiring Diagrams.
SPECIFICATIONS
STARTING SYSTEM
Starter Motor and Solenoid
Manufacturer Denso Denso Denso
Part Number 56028715AD 56027703AD 4741012
Engine Application 3.7L / 4.7L / 5.7L / 5.9L 8.0L 5.9L Diesel
Power Rating1.4 Kilowatt / 1.9
Horsepower1.4 Kilowatt / 1.9
Horsepower2.7 Kilowatt / 3.6
Horsepower
Voltage 12 Volts 12 Volts 12 Volts
Number of Brushes 4 4 4
Drive Type Gear Reduction Gear Reduction Conventional
Free Running Test Voltage 11 Volts 11 Volts 11 Volts
Free Running Test Amperage
Draw73 Amperes 73 Amperes 200 Amperes
Free Running Test Minimum
Speed3601 rpm 3601 rpm 3000
Solenoid Closing Maximum
Voltage Required7.5 Volts 7.5 Volts 8.0 Volts
* Cranking Amperage Draw
Test125 - 250 Amperes 125 - 250 Amperes 450 - 700 Amperes
* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
Fig. 6 TEST STARTER GROUND - TYPICAL
1 - STARTER MOTOR
2 - BATTERY
3 - VOLTMETER
DRSTARTING 8F - 33
STARTING (Continued)

SPECIFICATIONS - TORQUE - STARTING
SYSTEM
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Battery Cable Eyelet Nut at
Solenoid (large nut - gas engines)25 19 221
Battery Cable Eyelet Nut at
Solenoid (large nut - diesel engine)14 - 120
Starter Solenoid Nut (small nut -
diesel engine)6-55
Starter Mounting Bolts - Gas
Engines68 50 -
Starter Mounting Nut - Gas Engines 68 50 -
Starter Mounting Bolts - Diesel 43 32 -
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operation can be confirmed
by performing the following free running bench test.
This test can only be performed with starter motor
removed from vehicle. Refer to Specifications for
starter motor specifications.
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Mount starter motor securely in a soft-jawed
bench vise. The vise jaws should be clamped on the
mounting flange of starter motor. Never clamp on
starter motor by field frame.
(3) Connect a suitable volt-ampere tester and a
12-volt battery to starter motor in series, and set
ammeter to 100 ampere scale. See instructions pro-
vided by manufacturer of volt-ampere tester being
used.
(4) Install jumper wire from solenoid terminal to
solenoid battery terminal. The starter motor should
operate. If starter motor fails to operate, replace
faulty starter motor assembly.
(5) Adjust carbon pile load of tester to obtain free
running test voltage. Refer to Specifications for
starter motor free running test voltage specifications.
(6) Note reading on ammeter and compare reading
to free running test maximum amperage draw. Refer
to Specifications for starter motor free running test
maximum amperage draw specifications.
(7) If ammeter reading exceeds maximum amper-
age draw specification, replace faulty starter motor
assembly.
STARTER SOLENOID
This test can only be performed with starter motor
removed from vehicle.(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Disconnect wire from solenoid field coil termi-
nal.
(3) Check for continuity between solenoid terminal
and solenoid field coil terminal with a continuity
tester (Fig. 7). There should be continuity. If OK, go
to Step 4. If not OK, replace faulty starter motor
assembly.
(4) Check for continuity between solenoid terminal
and solenoid case (Fig. 8). There should be continuity.
If not OK, replace faulty starter motor assembly.
REMOVAL
3.7L / 4.7L
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Note: If equipped with 4WD and certain trans-
missions, a support bracket is used between front
axle and side of transmission. Remove 2 support
bracket bolts at transmission. Pry support bracket
slightly to gain access to lower starter mounting bolt.
Fig. 7 CONTINUITY BETWEEN SOLENOID AND
FIELD COIL TERMINALS - TYPICAL
1 - OHMMETER
2 - SOLENOID TERMINAL
3 - FIELD COIL TERMINAL
8F - 34 STARTINGDR
STARTING (Continued)

OPERATION
The heated seat module receives fused battery cur-
rent through the Integrated Power Module only when
the engine is running. The heated seat switches
receive battery current through fuse #48 in the Inte-
grated Power Module only when the ignition switch
is in the On position. The heated seat module shares
a common ground circuit with each of the heated seat
elements. The heated seat system will only operate
when the surface temperature of the seat cushion is
below the designed temperature set points of the sys-
tem.
The heated seat system will also automatically
turn off whenever the ignition switch is turned to
any position except On, or if the engine quits run-
ning. If the ignition switch is turned to the Off posi-
tion or if the engine quits running while a heated
seat is ON, the heated seat will remain Off after the
engine is restarted until a heated seat switch is
depressed again. This helps prevent the vehicles bat-
tery from being drained by the heated seat system.The heated seat module monitors inputs from the
heated seat sensors and the heated seat switches. In
response to these inputs the heated seat module uses
its internal programming to control 12v to the heated
seat elements in both front seats and to control the
heated seat LED indicator lamps located in both of
the heated seat switches. The heated seat module is
also programmed to provide self-diagnostics, if a
problem with the heated seat system is detected. If
the module detects certain failures within the heated
seat system, it will provide a visual indication of the
failure by flashing the indicator lamps in the appro-
priate heated seat switch. The heated seat module
will automatically turn off the heated seat elements
if it detects a short or open in the heated seat ele-
ment circuit or a heated seat sensor value that is out
of range.
DIAGNOSIS AND TESTING - HEATED SEAT
SYSTEM
HEATED SEAT SYSTEM SELF-DIAGNOSIS
The heated seat system is capable of performing
some self-diagnostics. The following table depicts the
various monitored failures which will be reported to
the vehicle operator or technician by flashing the
individual heated seat switch Light Emitting Diode
(LED) indicator lamps. Refer to the HEATED SEAT
SYSTEM SELF-DIAGNOSIS table for failure identi-
fication. The drivers heated seat switch indicator
lamps will flash if a failure occurs in the driver
heated seat, and the passengers heated seat switch
indicator lamps will flash for a passenger heated seat
failure. If a monitored heated seat system failure
occurs, the switch indicator lamps will flash at a
pulse rate of about one-half second on, followed by
about one-half second off for a duration of about one
minute after the switch for the faulty heated seat is
depressed in either the Low or High direction. This
process will repeat every time the faulty heated seat
switch is actuated until the problem has been cor-
rected.
HEATED SEAT SYSTEM SELF-DIAGNOSIS
Monitored FailureSwitch High
Indicator LampSwitch Low
Indicator Lamp
Heated Seat
Element ShortedFlashing Flashing
Heated Seat
Element OpenFlashing Off
Heated Seat
Sensor Value Out
of RangeOff Flashing
Fig. 1 DR Heated Seat System Diagram
1 - WIRE HARNESS
2 - DRIVER HEATED SEAT SWITCH
3 - PASSENGER HEATED SEAT SWITCH
4 - PASSENGER HEATED SEAT CUSHION ELEMENT
5 - SEAT CUSHION/BACK ELEMENT ELECTRICAL CONNECTOR
LOCATION
6 - DRIVER HEATED SEAT BACK ELEMENT
7 - DRIVER HEATED SEAT CUSHION ELEMENT
8 - HEATED SEAT MODULE
8G - 4 HEATED SEAT SYSTEMDR
HEATED SEAT SYSTEM (Continued)

HORN
TABLE OF CONTENTS
page page
HORN SYSTEM
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING - HORN SYSTEM . . . 1
HORN
DIAGNOSIS AND TESTING - HORN..........1REMOVAL.............................2
INSTALLATION..........................2
HORN SWITCH
DESCRIPTION..........................2
DIAGNOSIS AND TESTING - HORN SWITCH . . . 2
HORN SYSTEM
DESCRIPTION
The dual-note horn system features dual electro-
magnetic horn units. The horn system includes the
following major components:
²Horn- The two horns are located on the left
side of the engine compartment below the Integrated
Power Module (IPM).
²Horn Switch- The horn switch is molded into
the driver airbag trim cover.
OPERATION
The horn system operates on battery current
received through a fuse in the Integrated Power
Module (IPM). The horn system circuit is designed so
that the system will remain operational, regardless
of the ignition switch position.
DIAGNOSIS AND TESTING - HORN SYSTEM
The most reliable, efficient, and accurate
means to diagnose the horn system requires the
use of a DRBIIItscan tool and the proper Diag-
nostic Procedures manual. The DRBIIItscan
tool can provide confirmation that the PCI data
bus is functional, that all of the electronic mod-
ules are sending and receiving the proper mes-
sages on the PCI data bus, and that the horns
are being sent the proper hard wired outputs
for them to perform their functions.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
In most cases, any problem involving continually
sounding horns can be quickly alleviated by removing
the horn fuse from the Integrated Power Module
(IPM).WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
HORN
DIAGNOSIS AND TESTING - HORN
The most reliable, efficient, and accurate
means to diagnose the horn system requires the
use of a DRBIIItscan tool and the proper Diag-
nostic Procedures manual. The DRBIIItscan
tool can provide confirmation that the PCI data
bus is functional, that all of the electronic mod-
ules are sending and receiving the proper mes-
sages on the PCI data bus, and that the horns
are being sent the proper hard wired outputs
for them to perform their functions.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
DRHORN 8H - 1

IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION..........................1
SPECIFICATIONS
SPECIFICATIONS - TORQUE - IGNITION....3
ENGINE FIRING ORDER - 3.7L V-6.........4
ENGINE FIRING ORDER ± 4.7L V-8........4
FIRING ORDER / CABLE ROUTING ± 5.7L
V-8 ENGINE...........................4
ENGINE FIRING ORDER - 5.9L V-8.........4
SPARK PLUG CABLE ORDER ± 8.0L V-10
ENGINE..............................5
SPARK PLUG CABLE RESISTANCE........5
SPARK PLUGS........................5
IGNITION COIL RESISTANCE - 3.7L V-6.....6
IGNITION COIL RESISTANCE - 4.7L V-8.....6
IGNITION COIL RESISTANCE - 5.7L V-8.....6
IGNITION COIL RESISTANCE - 5.9L........6
IGNITION COIL RESISTANCE ± 8.0L V-10
ENGINE..............................6
IGNITION TIMING......................6
AUTOMATIC SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT.............6
OPERATION
OPERATION - PCM OUTPUT.............6
OPERATION - ASD SENSE - PCM INPUT....6
DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS........................7
REMOVAL.............................7
INSTALLATION..........................8
CAMSHAFT POSITION SENSOR
DESCRIPTION..........................8
OPERATION............................8
REMOVAL.............................11
INSTALLATION.........................14
DISTRIBUTOR
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................17INSTALLATION.........................18
DISTRIBUTOR CAP
DIAGNOSIS AND TESTING - DISTRIBUTOR
CAP - 5.9L V-8........................18
DISTRIBUTOR ROTOR
DIAGNOSIS AND TESTING - DISTRIBUTOR
ROTOR - 5.9L V-8.....................19
IGNITION COIL
DESCRIPTION.........................19
OPERATION...........................20
REMOVAL.............................23
INSTALLATION.........................24
KNOCK SENSOR
DESCRIPTION.........................25
OPERATION...........................25
REMOVAL.............................25
INSTALLATION.........................26
SPARK PLUG
DESCRIPTION.........................27
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS.........................27
REMOVAL.............................30
CLEANING
CLEANING AND ADJUSTMENT...........31
INSTALLATION.........................31
IGNITION COIL CAPACITOR
DESCRIPTION.........................33
OPERATION...........................33
REMOVAL.............................33
INSTALLATION.........................33
SPARK PLUG CABLE
DESCRIPTION.........................33
OPERATION...........................33
DIAGNOSIS AND TESTING - SPARK PLUG
CABLES............................33
REMOVAL.............................34
INSTALLATION.........................35
IGNITION CONTROL
DESCRIPTION
The ignition system is controlled by the Powertrain
Control Module (PCM) on all engines.
3.7L V-6 ENGINE
The 3.7L V-6 engine uses a separate ignition coil
for each cylinder. The one-piece coil bolts directly tothe cylinder head. Rubber boots seal the secondary
terminal ends of the coils to the top of all 6 spark
plugs. A separate electrical connector is used for each
coil.
Because of coil design, spark plug cables (second-
ary cables) are not used. A distributor is not used
with the 3.7L engine.
Two knock sensors (one for each cylinder bank) are
used to help control spark knock.
DRIGNITION CONTROL 8I - 1

The Auto Shutdown (ASD) relay provides battery
voltage to each ignition coil.
The ignition system consists of:
²6 Spark Plugs
²6 Separate Ignition Coils
²2 Knock Sensors
²Powertrain Control Module (PCM)
²Also to be considered part of the ignition system
are certain inputs from the Crankshaft Position,
Camshaft Position, Throttle Position, 2 knock and
MAP Sensors
4.7L V-8 ENGINE
The 4.7L V-8 engine uses a separate ignition coil for
each cylinder. The one-piece coil bolts directly to the
cylinder head. Rubber boots seal the secondary termi-
nal ends of the coils to the top of all 8 spark plugs. A
separate electrical connector is used for each coil.
Because of coil design, spark plug cables (second-
ary cables) are not used. A distributor is not used
with the 4.7L engine.
Two knock sensors (one for each cylinder bank) are
used to help control spark knock.
The Auto Shutdown (ASD) relay provides battery
voltage to each ignition coil.
The ignition system consists of:
²8 Spark Plugs
²8 Separate Ignition Coils
²2 Knock Sensors
²Powertrain Control Module (PCM)
²Also to be considered part of the ignition system
are certain inputs from the Crankshaft Position,
Camshaft Position, Throttle Position, 2 knock and
MAP Sensors
5.7L V-8 ENGINE
For additional information, also refer to Igni-
tion Coil Description and Operation.
The 5.7L V-8 engine is equipped with 16 spark
plugs. Two plugs are used for each cylinder. The 5.7L
is also equipped with 8 separate and independent
ignition coils. The one-piece coil bolts directly to the
cylinder head cover and attaches the coils secondary
output terminal directly to a spark plug using a rub-
ber boot seal. Each coil is also equipped with a sec-
ond output terminal. This second terminal connects a
conventional spark plug cable directly to a spark
plug on the opposite cylinder bank. A separate pri-
mary electrical connector is used for each coil.
Eight conventional spark plug cables are used with
the 5.7L. These cables connect a coil on one cylinder
bank, directly to a spark plug on the opposite cylin-
der bank. The cables are placed and routed in a spe-
cial plastic loom to keep them separated. This loom is
clipped to the intake manifold. To prevent a miss-
match of cables, a corresponding spark plug / coil
number is displayed on each plug cable: 1/6, 2/3, 4/7and 5/8. These numbers can also be found on the top
of the intake manifold to the right of the throttle
body (Fig. 1).
Two knock sensors (one for each cylinder bank) are
used to help control spark knock.
The 5.7L engine will not use a conventional distrib-
utor.
The ignition system consists of:
²16 Spark Plugs (2 per cylinder)
²
8 Separate, Dual-Secondary Output, Ignition Coils
²2 Knock Sensors
²8 Secondary Ignition Cables
²Powertrain Control Module (PCM)
²Also to be considered part of the ignition system
are certain inputs from the Crankshaft Position,
Camshaft Position, Throttle Position, 2 knock and
MAP Sensors
5.9L V-8 ENGINE
The 5.9L V-8 ignition system will use a conven-
tional distributor and 1 remotely mounted coil. Con-
ventional spark plug cables are used with the 5.9L.
Knock sensors are not used with the 5.9L engine.
The ignition system consists of:
²8 Spark Plugs
²1 Ignition Coil
²Secondary Ignition Cables
²Distributor (contains rotor and camshaft position
sensor)
²Powertrain Control Module (PCM)
Fig. 1 FIRING ORDER / CABLE ROUTING - 5.7L V-8
ENGINE
1 - TOP OF INTAKE MANIFOLD
2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER)
3 - CORRESPONDING SPARK PLUG NUMBER
8I - 2 IGNITION CONTROLDR
IGNITION CONTROL (Continued)

²Also to be considered part of the ignition system
are certain inputs from the Crankshaft Position, Cam-
shaft Position, Throttle Position and MAP Sensors
8.0L V-10 ENGINE
. The 8.0L V-10 engine is equipped with 2 remote
coil packs. Conventional spark plug cables are used
with the 8.0L engine. The 8.0L engine will not use a
conventional distributor
The ignition coils are individually fired, but each
coil is a dual output. Refer to Ignition Coil for addi-
tional information.Knock sensors are not used with the 8.0L engine.
The ignition system consists of:
²10 Spark Plugs
²2 Ignition Coil packs containing 10 individual
coils
²10 Secondary Ignition Cables
²Powertrain Control Module (PCM)
²Also to be considered part of the ignition system
are certain inputs from the Crankshaft Position,
Camshaft Position, Throttle Position and MAP Sen-
sors
SPECIFICATIONS
SPECIFICATIONS - TORQUE - IGNITION
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Camshaft Position Sensor - 3.7L V-6 Engine 12 - 106
Camshaft Position Sensor - 4.7L V-8 Engine 12 - 106
Camshaft Position Sensor - 5.7L V-8 Engine 12 9 105
Camshaft Position Sensor - 8.0L V-10 Engine 6 - 50
Crankshaft Position Sensor - 3.7L V-6 Engine 28 21 205
Crankshaft Position Sensor - 4.7L V-8 Engine 28 21 205
Crankshaft Position Sensor - 5.7L V-8 Engine 12 9 105
Crankshaft Position Sensor - 5.9L V-8 Engine 8 - 70
Crankshaft Position Sensor - 8.0L V-10 Engine 8 - 70
Distributor Hold Down Bolt - 5.9L V-8 Engine 23 17 -
Ignition Coil Mounting - 5.9L V-8 Engine
(if tapped bolts are used)5-50
Ignition Coil Mounting - 5.9L V-8 Engine
(if nuts/bolts are used)11 - 100
Ignition Coil Mounting - 3.7L V-6 Engine 8 - 70
Ignition Coil Mounting - 4.7L V-8 Engine 8 - 70
Ignition Coil Mounting - 5.7L V-8 Engine 12 9 105 (  20)
Ignition Coil Mounting - 8.0L V-10 Engine 10 - 90
* Knock Sensor - 3.7L V-6 Engine 20 15 176
* Knock Sensor - 4.7L V-8 Engine 20 15 176
* Knock Sensor - 5.7L V-8 Engine 20 15 176
Spark Plugs - 3.7L V-6 Engine 27 20 -
Spark Plugs - 4.7L V-8 Engine 27 20 -
** Spark Plugs - 5.7L V-8 Engine 18 (  3) 13 (  2) -
Spark Plugs - 5.9L V-8 Engine 41 30 -
Spark Plugs - 8.0L V-10 Engine 41 30 -
* Do not apply any sealant, thread-locker or adhesive
to bolts. Poor sensor performance may result.
** Torque critical tapered design. Do not exceed 15 ft.
lbs.
DRIGNITION CONTROL 8I - 3
IGNITION CONTROL (Continued)

8.0L V±10
If Replacing Old Sensor With Original
The camshaft position sensor is located on the tim-
ing chain case/cover on the left-front side of the
engine (Fig. 18).
When installing a used camshaft position sensor,
the sensor depth must be adjusted to prevent contact
with the camshaft gear (sprocket).
(1) Observe the face of the sensor. If any of the
original rib material remains (Fig. 19), it must be cut
down flush to the face of the sensor with a razor
knife. Remove only enough of the rib material until
the face of the sensor is flat. Do not remove more
material than necessary as damage to sensor may
result. Due to a high magnetic field and possible elec-
trical damage to the sensor, never use an electric
grinder to remove material from sensor.
(2) From the parts department, obtain a peel-and-
stick paper spacer (Fig. 19). These special paper
spacers are of a certain thickness and are to be used
as a tool to set sensor depth.
(3) Clean the face of sensor and apply paper
spacer (Fig. 19).
(4) Apply a small amount of engine oil to the sen-
sor o-ring (Fig. 20).
A low and high area are machined into the cam-
shaft drive gear (Fig. 21). The sensor is positioned in
the timing gear cover so that a small air gap (Fig.
21) exists between the face of sensor and the high
machined area of cam gear.
Before the sensor is installed, the cam gear may
have to be rotated. This is to allow the high
machined area on the gear to be directly in front of
the sensor mounting hole opening on the timing gear
cover.
Do not install sensor with gear positioned at
low area (Fig. 22) or (Fig. 21). When the engine
is started, the sensor will be broken.
(5) Using a 1/2 in. wide metal ruler, measure the
distance from the cam gear to the face of the sensor
mounting hole opening on the timing gear cover (Fig.
22).
(6) If the dimension is approximately 1.818 inches,
it is OK to install sensor. Proceed to step Step 9.
(7) If the dimension is approximately 2.018 inches,
the cam gear will have to be rotated.
(8) Attach a socket to the vibration damper mount-
ing bolt and rotate engine until the 1.818 inch
dimension is attained.
(9) Install the sensor into the timing case/cover
with a slight rocking action until the paper spacer
contacts the camshaft gear. Do not install the sensor
mounting bolt. Do not twist the sensor into position
as damage to the o-ring or tearing of the paper
spacer may result.(10) Scratch a scribe line into the timing chain
case/cover to indicate depth of sensor (Fig. 20).
(11) Remove the sensor from timing chain case/
cover.
(12) Remove paper spacer from sensor. This step
must be followed to prevent the paper spacer from
getting into the engine lubrication system.
(13) Again, apply a small amount of engine oil to
sensor o-ring.
(14) Again, install the sensor into the timing case/
cover with a slight rocking action until the sensor is
aligned to scribe line.
(15) Install sensor mounting bolt and tighten to 6
N´m (50 in. lbs.) torque.
(16) Connect engine wiring harness to sensor.
Replacing With a New Sensor
(1) Apply a small amount of engine oil to the sen-
sor o-ring (Fig. 20).
A low and high area are machined into the cam-
shaft drive gear (Fig. 21). The sensor is positioned in
the timing gear cover so that a small air gap (Fig.
21) exists between the face of sensor and the high
machined area of cam gear.
Before the sensor is installed, the cam gear may
have to be rotated. This is to allow the high
machined area on the gear to be directly in front of
the sensor mounting hole opening on the timing gear
cover.
Fig. 21 SENSOR OPERATION ± 8.0L V-10 ENGINE
1 - CAM DRIVE GEAR
2 - LOW MACHINED AREA
3 - HIGH MACHINED AREA
4 - CAMSHAFT POSITION SENSOR
5 - AIR GAP
DRIGNITION CONTROL 8I - 15
CAMSHAFT POSITION SENSOR (Continued)

4.7L V-8
Battery voltage is supplied to the 8 individual igni-
tion coils from the ASD relay. The Powertrain Con-
trol Module (PCM) opens and closes each ignition coil
ground circuit at a determined time for ignition coil
operation.
Base ignition timing is not adjustable.By con-
trolling the coil ground circuit, the PCM is able to set
the base timing and adjust the ignition timing
advance. This is done to meet changing engine oper-
ating conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
Because of coil design, spark plug cables (second-
ary cables) are not used with the 4.7L V-8 engine.
5.7L V-8
The ignition system is controlled by the Powertrain
Control Module (PCM) on all engines.
A ªwasted sparkº system is used on the 5.7L
engine combining paired, or dual-firing coils, and 2
spark plugs per cylinder. The coils and spark plugs
are connected with paired, secondary high-voltage
cables.
Each cylinder is equipped with 1 dual-output coil.
Meaning one coil mounts directly over one of the
dual spark plugs for 1 high-voltage output. A second
high-voltage output is supplied directly from the
same coil (using a plug cable) to one of the dual
spark plugs on a corresponding (paired) cylinder on
the opposite cylinder bank.
Each coil fires 2 spark plugs simultaneously on
each of the cylinder banks (one cylinder on compres-
sion stroke and one cylinder on exhaust stroke).
EXAMPLE :When the #1 cylinder is on compression
stroke and ready for spark, the #1 coil will fire one of
the dual spark plugs on the #1 cylinder (directly
below the coil). The other dual spark plug on the #1
cylinder will be fired by the #6 coil. At the same
time, the #1 coil will fire a ªwasted sparkº to one of
the dual spark plugs at the #6 cylinder as coil #6 also
fires a ªwasted sparkº to one of the dual spark plugs
at the #6 cylinder.
The firing order is paired at cylinders 1/6, 2/3, 4/7,
5/8. Basic cylinder firing order is 1±8±4±3±6±5±7±2.
Battery voltage is supplied to all of the ignition
coils positive terminals from the ASD relay. If the
PCM does not see a signal from the crankshaft and
camshaft sensors (indicating the ignition key is ON
but the engine is not running), it will shut down the
ASD circuit.
Base ignition timing is not adjustable on the
5.7L V-8 engine.By controlling the coil ground cir-
cuits, the PCM is able to set the base timing andadjust the ignition timing advance. This is done to
meet changing engine operating conditions.
The PCM adjusts ignition timing based on inputs it
receives from:
²The engine coolant temperature sensor
²The crankshaft position sensor (engine speed)
²The camshaft position sensor (crankshaft posi-
tion)
²The manifold absolute pressure (MAP) sensor
²The throttle position sensor
²Transmission gear selection
5.9L V-8
A single ignition coil is used. The Powertrain Con-
trol Module (PCM) opens and closes the ignition coil
ground circuit for ignition coil operation.
Battery voltage is supplied to the ignition coil pos-
itive terminal from the ASD relay. If the PCM does
not see a signal from the crankshaft and camshaft
sensors (indicating the ignition key is ON but the
engine is not running), it will shut down the ASD cir-
cuit.
Base ignition timing is not adjustable on any
engine.By controlling the coil ground circuit, the
PCM is able to set the base timing and adjust the
ignition timing advance. This is done to meet chang-
ing engine operating conditions.
Conventional spark plug cables (secondary cables)
are used with the 5.9L V-8 engine.
8.0L V-10
When one of the 5 independent coils discharges, it
fires two paired cylinders at the same time (one cyl-
inder on compression stroke and the other cylinder
on exhaust stroke).
Coil firing is paired together on cylinders:
²Number 5 and 10
²Number 9 and 8
²Number 1 and 6
²Number 7 and 4
²Number 3 and 2
The ignition system is controlled by the Powertrain
Control Module (PCM) on all engines.
Battery voltage is supplied to all of the ignition
coils positive terminals from the ASD relay. If the
PCM does not see a signal from the crankshaft and
camshaft sensors (indicating the ignition key is ON
but the engine is not running), it will shut down the
ASD circuit.
Conventional spark plug cables (secondary cables)
are used with the 8.0L V-10 engine.
Base ignition timing is not adjustable on the
8.0L V-10 engine.By controlling the coil ground cir-
cuits, the PCM is able to set the base timing and
adjust the ignition timing advance. This is done to
meet changing engine operating conditions.
8I - 22 IGNITION CONTROLDR
IGNITION COIL (Continued)

WARNING: 5.9L V-8 LDC-GAS ENGINES: DO NOT
REMOVE THE COIL MOUNTING BRACKET-TO-CYL-
INDER HEAD MOUNTING BOLTS. THE COIL
MOUNTING BRACKET IS UNDER ACCESSORY
DRIVE BELT TENSION. IF THIS BRACKET IS TO BE
REMOVED FOR ANY REASON, ALL BELT TENSION
MUST FIRST BE RELIEVED. REFER TO THE BELT
SECTION OF GROUP 7, COOLING SYSTEM.
5.9L V-8 HDC-Gas Engine: The coil is mounted to
a bracket that is bolted to the air injection pump
(AIR pump) mounting bracket (Fig. 36).
(1) Disconnect primary coil connector from ignition
coil.
(2) Disconnect secondary cable from ignition coil.
(3) Remove ignition coil from coil mounting
bracket (two bolts).
8.0L V-10
Two separate coil packs containing a total of five
independent coils are attached to a common mount-
ing bracket located above the right engine valve
cover (Fig. 37). The front and rear coil packs can be
serviced separately.
(1) Depending on which coil is being removed, the
throttle body air intake tube or intake box may need
to be removed to gain access to coils.
(2) Remove secondary spark plug cables from coil
packs. Note position of cables before removal.
(3) Disconnect primary wiring harness connectors
at coil packs.
(4) Remove four (4) coil pack-to-coil mounting
bracket bolts for coil pack being serviced (Fig. 37).
(5) Remove coil(s) from mounting bracket.
INSTALLATION
3.7L V-6
(1) Using compressed air, blow out any dirt or con-
taminants from around top of spark plug.
(2) Check condition of coil o-ring and replace as
necessary. To aid in coil installation, apply silicone to
coil o-ring.
(3) Position ignition coil into cylinder head opening
and push onto spark plug. Do this while guiding coil
base over mounting stud.
(4) Install coil mounting stud nut. Refer to torque
specifications.
(5) Connect electrical connector to coil by snapping
into position.
(6) If necessary, install throttle body air tube.
4.7L V-8
(1) Using compressed air, blow out any dirt or con-
taminants from around top of spark plug.
(2) Check condition of coil o-ring and replace as
necessary. To aid in coil installation, apply silicone to
coil o-ring.
(3) Position ignition coil into cylinder head opening
and push onto spark plug. Do this while guiding coil
base over mounting stud.
(4) Install coil mounting stud nut. Refer to torque
specifications.
(5) Connect electrical connector to coil by snapping
into position.
(6) If necessary, install throttle body air tube.
5.7L V-8
(1) Using compressed air, blow out any dirt or con-
taminants from around top of spark plug.
(2) Before installing spark plug cables to either the
spark plugs or coils, or before installing a coil to a
spark plug, apply dielectric grease to inside of boots.
(3) Position ignition coil into cylinder head opening
and push onto spark plug. Twist coil into position.
(4) Install 2 coil mounting bolts. Refer to torque
specifications.
(5) Connect electrical connector to coil by snapping
into position.
(6) Install cable to coil. To prevent ignition cross-
fire, spark plug cablesMUSTbe placed in cable tray
(routing loom) into their original position. Refer to
Spark Plug Cable Removal for a graphic.
(7) If necessary, install throttle body air tube.
5.9L V-8
The ignition coil is an epoxy filled type. If the coil
is replaced, it must be replaced with the same type.
(1) Install ignition coil to coil bracket. If nuts and
bolts are used to secure coil to coil bracket, tighten to
11 N´m (100 in. lbs.) torque. If coil mounting bracket
has been tapped for coil mounting bolts, tighten bolts
to 5 N´m (50 in. lbs.) torque.
(2) Connect all wiring to ignition coil.
8.0L V-10
(1) Position coil packs to mounting bracket (prima-
ry wiring connectors face downward).
(2) Install coil pack mounting bolts. Tighten bolts
to 10 N´m (90 in. lbs.) torque.
(3) Install coil pack-to-engine mounting bracket (if
necessary).
(4) Connect primary wiring connectors to coil
packs (four wire connector to front coil pack and
three wire connector to rear coil pack).
(5) Connect secondary spark plug cables to coil
packs. Refer to (Fig. 38) for correct cable order.
8I - 24 IGNITION CONTROLDR
IGNITION COIL (Continued)