Ignition Coil: Service and Repair

Ignition Coil Replacement

Removal Procedure




1. Remove the intake manifold sight shield, as required.
2. If replacing one of the rear 2 ignitions coils on the right side perform steps 3 through 12, otherwise proceed to step 13.
3. Disconnect the engine wiring harness electrical connector (3) from the drive motor generator power inverter module cover.
4. Loosen the drive motor generator power inverter module cover bolt (1).
5. Remove the drive motor generator power inverter module cover (2).




6. Remove the generator control module 3 phase cable clip nut (1).
7. Remove the generator control module 3 phase cable clip from the engine bracket (2).
8. Reposition the generator control module 3 phase cables out of the way.
9. Remove the right wheelhouse liner.




10. Working through the wheel opening, remove the engine bracket bolts (2).
11. Lower the vehicle.
12. Remove the engine bracket nut (1) from the ignition coil bracket stud and remove the bracket (3).




13. Disconnect the ignition coil wiring harness electrical connector (1) from the ignition coil.




14. Remove the spark plug wire from the ignition coil.

* Twist the spark plug wire boot a 1/2 turn.
* Pull only on the boot in order to remove the wire from the ignition coil.

15. Remove the ignition coil bolts.
16. Remove the ignition coil from the bracket.
17. There are 2 different manufacturers for the ignition coils and coil brackets. They are as follows:




18. The Melco(R) (1) ignition coil is a square design.
19. The Delphi(R) (2) ignition coil is a round design.




20. The Melco(R) ignition coil bracket (1) is a square design.
21. The Delphi(R) ignition coil bracket (2) is a round design.

Installation Procedure




1. Position the ignition coil to the ignition coil bracket.

Notice: Refer to Fastener Notice.

2. Install the ignition coil bolts.

Tighten the bolts to 10 N.m (89 lb in).

3. Install the spark plug wire to the ignition coil.
4. Inspect the spark plug wire for proper installation:

* Push sideways on each boot in order the inspect the seating.
* Reinstall any loose boot.




5. Connect the ignition coil wiring harness electrical connector (1) to the ignition coil.
6. If replacing one of the rear 2 ignitions coils on the right side perform steps 7 through 16, otherwise proceed to step 17.




7. Install the engine bracket (3) to the ignition coil bracket stud and install nut (1).

Tighten the nut to 9 N.m (80 lb in).

8. Raise the vehicle half way.
9. Working through the wheel opening, install the engine bracket bolts (2).

Tighten the bolts to 50 N.m (37 lb ft).




10. Install the right wheelhouse liner.
11. Position the generator control module 3 phase cables to the bracket channel.
12. Install the generator control module 3 phase cable clip to the tab (3) on the engine bracket (2).
13. Install the generator control module 3 phase cable clip nut (1).

Tighten the nut to 9 N.m (80 lb in).




14. Install the drive motor generator power inverter module cover (2).
15. Tighten the drive motor generator power inverter module cover bolt (1).

Tighten the bolt to 1.5 N.m (13 lb in).

16. Connect the engine wiring harness electrical connector (3) to the drive motor generator power inverter module cover.
17. Install the intake manifold sight shield, as required.