Mechanical Gas Fuel System G5.9, G8.3, G855 – Master Repair Manual 013-015   Spark Plugs (Shielded)

Remove

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Disconnect the spark plug wire (1) from the ignition coil (2) and the spark plug extension (3).

Remove the spark plug extension.

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 CAUTION 

Do not let the spark plug fall into its well. Damage to the insulator can result. If the spark plug falls into the well, replace it with a new spark plug.

Use a 7/8-inch thin wall magnetic socket to remove the spark plug.

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Clean and Inspect for Reuse

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 WARNING 

When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

Spark plugs must always be kept clean.

Never touch the porcelain of the spark plug, spark plug extension, or spark plug wire.

If the porcelain becomes dirty, it must be cleaned before installation.

Cleaning can be done with 100 percent isopropyl alcohol with no additives and a clean cloth.

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Inspect the spark plug for the following problems:

  1. Insulator flashover
  2. Electrode deposits or fouling
  3. Worn or missing electrode.

If a spark plug exhibits any of these problems, the spark plug must be replaced.

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Inspect the spark plug for the following problems.

  1. Cracked insulator
  2. Electrode misalignment
  3. Corona marks.

If a spark plug exhibits any of these problems, the spark plug must be replaced.

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Install

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The spark plug socket used for installation must be kept clean.

Do not use a spark plug socket with a rubber insert. Rubber inserts can contaminate the clean spark plugs.

Use a 7/8-inch thin wall magnetic socket for shielded ignition systems.

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Spark plug threads have anti-seize plating.

Anti-seize compound is generally conductive and must not
be used on spark plugs.

 
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Spark plugs must always be tightened to the correct torque value.

On a hot engine, tighten all spark plugs hand tight before tightening the first spark plug with a torque wrench. This will allow all of the spark plugs to warm up to the cylinder head temperature prior to tightening.

Tighten the spark plugs.

Torque Value:  38  n.m  [28 ft-lb]

NOTE: Once installed, do not remove the spark plug until the next maintenance interval. The crush washer gasket is single-use only and can not be reused.

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Install the spark plug extension (3).

Torque Value:  3  n.m  [26 in-lb]

Install the spark plug wire (1) onto the ignition coil (2) and the spark plug extension (3).

Torque both ends of the spark plug wire.

Torque Value:  3  n.m  [26 in-lb]

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Last Modified:  20-Jul-2006