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Spark Plug gap for 1997 Plymouth voyager 2.4 liter engine is .040". My 1996 Voyager w/ 2.4L emissions label says 0.050" gap for the Champion RC12YC5 plugs I just replaced. Those and former Bosch platinum plugs started misfiring after ~20,000 miles. Occured at wider throttle opening, especially low rpm, where cylinder pressure is high (harder to jump gap). I had suspected thin, brittle platinum wires were breaking internally, but the latest failure occured w/ copper plugs, so I now suspect wear to ~0.055" gap causes the misfiring. There is a TSB for 2.4L non-turbo PT Cruisers to reduce the gap to 0.040", so perhaps good for Voyagers too. Next time I will set a 0.045" gap since going too low affects mileage and emissions (Chrysler probably pushed the limit for better specs). The first time I had a problem, I changed the plug wires and coil pack. With an MS in Mech Engr, I lectured my wife that her suggestion "maybe the spark plugs" was folly since "the spark plugs look fine" and "they never fail". Turned out she was right. If anyone finds plugs or a gap that works great, please post. I question exotic plugs like split-fire or pulsar. Note their dyno plots always run the regular plugs first when perhaps the engine was cold.
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∙ 15y ago
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