Mechanical Gas Fuel System G5.9, G8.3, G855 – Master Repair Manual 013-045   Spark Plug Wire (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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Clean and Inspect for Reuse

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Use a lint-free cloth or cotton swab and 100 percent isopropyl alcohol with no additives to clean the porcelain of the spark plug extension and the spark plug wire.

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Inspect the spark plug wire and spark plug extension for melting and cracks.

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

If any damage is found, replace the damaged components.

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There are two different types of spark plug extensions; extensions equipped with a spindle retaining o-ring and extensions that are not equipped with a spindle retaining o-ring.

Extensions equipped with a spindle retaining o-ring have a shoulder in the spindle spark plug end (1), while extensions that are not equipped with a spindle retaining o-ring do not have a shoulder in the spindle spark plug end (2).

 
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If the spark plug extension is equipped with a spindle retaining o-ring, hold the spark plug wire extension (1) in a vertical position with one hand, while placing the other hand below, as shown in the illustration.

If the spindle (2) slides out of the extension, the internal retainer o-ring needs to be replaced. Replacement instructions are provided in the Assemble section

 
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Check the spark plug wire for breaks or fraying.

Check the valve cover rubber grommet for cracks or breaks.

If any damage is found, replace the damaged components.

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

Replace the spark plug wire if resistance is found outside of specification.

Application
Wire Resistance
G/GTA5.9
G/GTA8.3
GTA855 G-Drive
G/GTA855
GTA14
GTA19
GTA28
GTA38
GTA50
KTA19GC shielded ignition
Less than 1000 ohms
KTA38GC shielded ignition
Less than 10 ohms

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Disassemble

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Dissasembly of the spark plug extension is only required when instructed in the Clean and Inspect for Reuse section or for spindle replacement. If disassembly is not required, go to the Install section

To disassemble, gently pull the spindle (1) out from the extension tube (2).

If damaged, remove and discard the retaining o-ring.

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Firmly press to slide the rubber grommet (1) over the hex end of the spark plug extension (2).

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Assemble

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Assembly is only required when the spark plug extension has been disassembled.

Carefully slide the retaining o-ring (1) onto the spindle.

Hold the spindle in a vertical position and place the retaining o-ring approximately 1 inch [25.4mm] from the top of the spring (3) as shown in the illustration.

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Slide the spindle (1) into the extension tube (2) until it stops

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If the rubber grommet needs to be replaced, firmly press to slide the rubber grommet (1) over the hex end of the spark plug extension (2).

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Install

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Install the spark plug extension (3).

Torque Value:  3  n.m  [27 in-lb]

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

Torque Value:  3  n.m  [27 in-lb]

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Last Modified:  25-May-2010