Mechanical Gas Fuel System G5.9, G8.3, G855 – Master Repair Manual 013-014   Spark Plug Wire (Non Shielded)

Remove

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 CAUTION 

Do not pull on the spark plug wire during removal. Damage to the wire can result. To remove the wire, pull on the coil boot and spark plug wire boot.

Disconnect the spark plug wire (1) from the ignition coil and remove the wire (2) from the valve cover.

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Clean and Inspect for Reuse

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Use a lint free cloth or cotton swab and 100 percent isopropyl alcohol, with no additive, to clean the spark plug opening on the spark plug wire.

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Inspect the spark plug wire for melting and cracks.

Inspect the spark plug wire for any cracks and spark carryover.

If any damage is found, replace the spark plug wire.

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Measure the resistance of the spark plug wire using a multimeter.

Application Wire Resistance
G/GTA5.9, G/GTA8.3, G/GTA855, GTA14, GTA19, GTA28, GTA38, GTA50, KTA19GC Less than 1000 ohms
KTA38GC Standard Ignition 8,000 to 12,000 ohms

If the resistance is outside of the specification, replace the spark plug wire.

 
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Check the spark plug wire for breaks or fraying.

Check the spark plug rubber boot for damage.

If any damage is found, replace the spark plug wire.

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Install

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 CAUTION 

Lubriplate™, Part Number 3822934, does not meet the specification for dielectric grease.

Cummins Inc. recommends the following dielectric grease:

  • Dupont Krytox 205, Cummins Part Number 3164956.

Apply a small amount of dielectric lubricant to the spark plug wire o-ring prior to installation. This adds to the dielectric seal of the rubber boot and reduces the possibility of the boot melting onto the spark plug.

NOTE: The KTA38GC spark plug wire does not have an o-ring and therefore does not require dielectric lubricant.

 
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Install the wire (2) in the valve cover.

Install the spark plug wire (1) onto the ignition coil.

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Last Modified:  09-Aug-2006