HOWTO_Spark Plugs
1994 Dodge Caravan, 3.3L
COMPONENT INFO
1) Firing Order (1,2,3,4,5,6)
Cylinder Numbering (Front to Rear)
Front Bank (2, 4, 6)
Rear Bank (1, 3, 5)
2) Champion Double Platinum (per forum) on newer Caravans to prolong plug life because of the
difficulty of changing the back plugs.
3) Removed Champion #4405 (Truck Plug).
Installed Autolite AP646 with gasket seat.
4) Plug diameter (thread) = 14mm
Reach = ??
Use Gasket Seat NOT Tapered Seat (is this OEM??)
Gap Setting: .050 inch (1.3mm); Use two numbered drill bits, one larger one smaller
to confirm gap as cannot find a gap setter anywhere with this size wire.
Torque Specs (14mm plug into aluminum head per Autolite table) is: 15-22 ft. lbs.
Use Antiseize compound if plug not factory coated.
INSTALLATION
The most difficult part of this installation is getting the plug boots On and Off.
Front Plugs
1) Loosen heat shield surrounding the plugs (4 bolts)
2) Try and twist plug boot to loosen it.
3) Use either a standard spark plug tool or KD’s T plug tool (Plastic with half plug and T handle)
to pull boots.
4) Examine wires for cracking.
5) Use air hose or canned air to blow around plug and remove any dirt / debris.
6) Remove and install plugs. Torque to specs.
7) Coat inside of each plug boot with silicone grease and install boot.
Back Plugs (I found the following easier than all other forum and internet suggested methods)
NO NEED TO GO UNDERNEATH or REMOVE MANIFOLD, SERPENTINE BELT and ALTERNATOR, BATTERY, AIR BOX, WIPER ASSEMBLY or any other parts
1) Remove Oxygen Sensor Connector (has plastic clip holding connector to bracket) and set aside
(Tie off or position connector so it doesn’t fall behind engine)
2) Remove Oxygen Sensor Bracket (13mm bolt). There is a grounding strap that goes behind the bolt
with the other end attached to the firewall.
3) Detach PCV value near value and lay value and hose on manifold.
4) Remove Manifold Absolute Pressure (MAP) Sensor
-- This is plastic box to the right of the Oxygen Sensor. (13 mm bolt)
INSTALL, requires silicon sealant -- (I used high temp copper because this is what I had).
5) Get a 24 inch piece of ¼ to 3/8 inch diameter rope (cotton over nylon best).
6) Try and twist boot by hand as much as possible.
Loop rope around the T on “KD’s T Boot Removal Tool” (they may have a longer handled one). Position T Boot Removal Tool With Left Hand while holding the Rope above, over and behind the Manifold with the Right Hand. Pull rope and remove each plug boot in turn.
7) Use air hose (canned air) to blow around plug and remove any dirt / debris.
8) Use plug socket, universal joint, ratchet and extensions to remove and install new plugs.
(Do Not Forget Antisieze Compound if plugs are not factory conditioned)
9) Coat inside of each plug boot with silicone grease.
10) For the back passenger side plug boots you can reach straight down and to your right.
11) For the center and driver side plug boots:
a) Lay a towel or pad on top of the manifold;
b) Stretch yourself over the manifold so your head is over the front passenger fender and your right
leg is over the front driver fender;.
c) Using your right hand, stick it through the opening where the Oxygen Sensor bracket was mounted,
and “attempt” to replace the boots. For my arm length the center was more difficult.
1994 Dodge Caravan, 3.3L
COMPONENT INFO
1) Firing Order (1,2,3,4,5,6)
Cylinder Numbering (Front to Rear)
Front Bank (2, 4, 6)
Rear Bank (1, 3, 5)
2) Champion Double Platinum (per forum) on newer Caravans to prolong plug life because of the
difficulty of changing the back plugs.
3) Removed Champion #4405 (Truck Plug).
Installed Autolite AP646 with gasket seat.
4) Plug diameter (thread) = 14mm
Reach = ??
Use Gasket Seat NOT Tapered Seat (is this OEM??)
Gap Setting: .050 inch (1.3mm); Use two numbered drill bits, one larger one smaller
to confirm gap as cannot find a gap setter anywhere with this size wire.
Torque Specs (14mm plug into aluminum head per Autolite table) is: 15-22 ft. lbs.
Use Antiseize compound if plug not factory coated.
INSTALLATION
The most difficult part of this installation is getting the plug boots On and Off.
Front Plugs
1) Loosen heat shield surrounding the plugs (4 bolts)
2) Try and twist plug boot to loosen it.
3) Use either a standard spark plug tool or KD’s T plug tool (Plastic with half plug and T handle)
to pull boots.
4) Examine wires for cracking.
5) Use air hose or canned air to blow around plug and remove any dirt / debris.
6) Remove and install plugs. Torque to specs.
7) Coat inside of each plug boot with silicone grease and install boot.
Back Plugs (I found the following easier than all other forum and internet suggested methods)
NO NEED TO GO UNDERNEATH or REMOVE MANIFOLD, SERPENTINE BELT and ALTERNATOR, BATTERY, AIR BOX, WIPER ASSEMBLY or any other parts
1) Remove Oxygen Sensor Connector (has plastic clip holding connector to bracket) and set aside
(Tie off or position connector so it doesn’t fall behind engine)
2) Remove Oxygen Sensor Bracket (13mm bolt). There is a grounding strap that goes behind the bolt
with the other end attached to the firewall.
3) Detach PCV value near value and lay value and hose on manifold.
4) Remove Manifold Absolute Pressure (MAP) Sensor
-- This is plastic box to the right of the Oxygen Sensor. (13 mm bolt)
INSTALL, requires silicon sealant -- (I used high temp copper because this is what I had).
5) Get a 24 inch piece of ¼ to 3/8 inch diameter rope (cotton over nylon best).
6) Try and twist boot by hand as much as possible.
Loop rope around the T on “KD’s T Boot Removal Tool” (they may have a longer handled one). Position T Boot Removal Tool With Left Hand while holding the Rope above, over and behind the Manifold with the Right Hand. Pull rope and remove each plug boot in turn.
7) Use air hose (canned air) to blow around plug and remove any dirt / debris.
8) Use plug socket, universal joint, ratchet and extensions to remove and install new plugs.
(Do Not Forget Antisieze Compound if plugs are not factory conditioned)
9) Coat inside of each plug boot with silicone grease.
10) For the back passenger side plug boots you can reach straight down and to your right.
11) For the center and driver side plug boots:
a) Lay a towel or pad on top of the manifold;
b) Stretch yourself over the manifold so your head is over the front passenger fender and your right
leg is over the front driver fender;.
c) Using your right hand, stick it through the opening where the Oxygen Sensor bracket was mounted,
and “attempt” to replace the boots. For my arm length the center was more difficult.