Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Spark Plugs

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Inspection & Gapping



A typical spark plug consists of a metal shell surrounding a ceramic insulator. A metal electrode extends downward through the center of the insulator and protrudes a small distance. Located at the end of the plug and attached to the side of the outer metal shell is the side electrode. The side electrode bends in at a 90 degrees angle so its tip is just past and parallel to the tip of the center electrode. The distance between these 2 electrodes (measured in thousandths of an inch or hundredths of a millimeter) is called the spark plug gap.

The spark plug does not produce a spark but instead provides a gap across which the current can arc. The coil produces anywhere from 20,000-50,000 volts (depending on the type and application) which travels through the wires to the spark plugs. The current passes along the center electrode and jumps the gap to the side electrode, and in doing so, ignites the air/fuel mixture in the combustion chamber.

Click image to see an enlarged view

Fig. Cross-section of a spark plug



Click image to see an enlarged view

Fig. Spark plug heat range



Click image to see an enlarged view

Fig. Spark plug inspection

A typical spark plug consists of a metal shell surrounding a ceramic insulator. A metal electrode extends downward through the center of the insulator and protrudes a small distance. Located at the end of the plug and attached to the side of the outer metal shell is the side electrode. The side electrode bends in at a 90 degrees angle so its tip is just past and parallel to the tip of the center electrode. The distance between these 2 electrodes (measured in thousandths of an inch or hundredths of a millimeter) is called the spark plug gap.

The spark plug does not produce a spark but instead provides a gap across which the current can arc. The coil produces anywhere from 20,000-50,000 volts (depending on the type and application) which travels through the wires to the spark plugs. The current passes along the center electrode and jumps the gap to the side electrode, and in doing so, ignites the air/fuel mixture in the combustion chamber.

Click image to see an enlarged view

Fig. Cross-section of a spark plug

A typical spark plug consists of a metal shell surrounding a ceramic insulator. A metal electrode extends downward through the center of the insulator and protrudes a small distance. Located at the end of the plug and attached to the side of the outer metal shell is the side electrode. The side electrode bends in at a 90 degrees angle so its tip is just past and parallel to the tip of the center electrode. The distance between these 2 electrodes (measured in thousandths of an inch or hundredths of a millimeter) is called the spark plug gap.

The spark plug does not produce a spark but instead provides a gap across which the current can arc. The coil produces anywhere from 20,000-50,000 volts (depending on the type and application) which travels through the wires to the spark plugs. The current passes along the center electrode and jumps the gap to the side electrode, and in doing so, ignites the air/fuel mixture in the combustion chamber.

Click image to see an enlarged view

Fig. Cross-section of a spark plug

Removal & Installation




NOTE
All models were originally equipped with platinum-tip spark plugs which can be used for as-long-as 100,000 miles (161,000 km). This holds true unless internal engine wear or damage and/or improperly operating emissions controls cause plug fouling. If you suspect this, you may wish to remove and inspect the platinum plugs before the recommended mileage. Most platinum plugs should not be cleaned or re-gapped. If you find their condition unsuitable, they should be replaced.

When removing the spark plugs, work on 1 at a time . Don't start by removing the plug wires all at once because unless you number them, they're going to get mixed up. On some models though, it will be more convenient for you to remove all of the wires before you start to work on the plugs. If this is necessary, take a minute before you begin and number the wires with tape before you take them off. The time you spend here will pay off later.

  1. Disconnect the negative battery cable, and if the vehicle has been run recently, allow the engine to thoroughly cool. Attempting to remove plugs from a hot cylinder head could cause the plugs to seize and damage the threads in the cylinder head.
  2.  
  3. Check for access to the plugs on your vehicle. The wheel wells of most vans are designed to allow access to the sides of the engine. A rubber cover may be draped over the opening, and it may require removal of 1 or more plastic body snap-fasteners (which are carefully pried loose using a special C-shaped tool) before you can move it aside for clearance. If this is your best access point, raise and support the vehicle safely then remove the front tire and wheel assemblies.
    NOTE
    On some models, the engine cover may be removed to provide additional access to the spark plugs. This will be necessary if you also plan to check the spark plug wires at this time anyway.

  4.  
  5. Carefully twist the spark plug wire boot to loosen it, then pull upward and remove the boot from the plug. Be sure to pull on the boot and not on the wire, otherwise the connector located inside the boot may become separated.
    NOTE
    A spark plug wire removal tool is recommended as it will make removal easier and help prevent damage to the boot and wire assembly.



    Click image to see an enlarged view

    Fig. Disconnect the spark plug wire by pulling on the BOOT, NOT THE WIRE



    Click image to see an enlarged view

    Fig. A spark plug wire removal tool is recommended to prevent wire damage (and to make it easier)

  6.  
  7. Using compressed air (and SAFETY GLASSES), blow any water or debris from the spark plug well to assure that no harmful contaminants are allowed to enter the combustion chamber when the spark plug is removed. If compressed air is not available, use a rag or a brush to clean the area.
    NOTE
    Remove the spark plugs when the engine is cold, if possible, to prevent damage to the threads. If plug removal is difficult, apply a few drops of penetrating oil or silicone spray to the area around the base of the plug, and allow it a few minutes to work.

  8.  
  9. Using a spark plug socket (usually a 5 / 8 in. socket on these engines) that is equipped with a rubber insert to properly hold the plug, turn the spark plug counterclockwise to loosen and remove the spark plug from the bore.
    WARNING
    AVOID the use of a flexible extension on the socket. Use of a flexible extension may allow a shear force to be applied to the plug. A shear force could break the plug off in the cylinder head, leading to costly and frustrating repairs.



    Click image to see an enlarged view

    Fig. Loosen the spark plug using a ratchet and extension . . .



    Click image to see an enlarged view

    Fig. . . . then carefully unthread and remove the plug from the cylinder head

  10.  

To install:

  1. Inspect the spark plug boot for tears or damage. If a damaged boot is found, the spark plug wire must be replaced. As mentioned earlier, this is an excellent time to check each of the spark plug wires for proper resistance and/or for damage.
  2.  
  3. Using a wire feeler gauge, check and adjust the spark plug gap. When using a gauge, the proper size should pass between the electrodes with a slight drag. The next larger size should not be able to pass while the next smaller size should pass freely.
  4.  
  5. Carefully thread the plug into the bore by hand. If resistance is felt before the plug is almost completely threaded, back the plug out and begin threading again. In small, hard to reach areas, an old spark plug wire and boot could be used as a threading tool. The boot will hold the plug while you twist the end of the wire and the wire is supple enough to twist before it would allow the plug to crossthread.
    WARNING
    Do not use the spark plug socket to thread the plugs. Always carefully thread the plug by hand or using an old plug wire to prevent the possibility of crossthreading and damaging the cylinder head bore.

  6.  
  7. Carefully tighten the spark plug. Refer to the Torque Specifications chart for tightening torque.
  8.  
  9. Apply a small amount of silicone dielectric compound to the end of the spark plug lead or inside the spark plug boot to prevent sticking, then install the boot to the spark plug and push until it clicks into place. The click may be felt or heard, then gently pull back on the boot to assure proper contact.
  10.  

  1. Remove the spark plug wire. Twist the boot and pull only on the boot, never on the wire.
  2.  
  3. Loosen the spark plug 1 or 2 turns.
  4.  
  5. Brush or using compressed air, blow away any dirt from around the spark plug.
  6.  
  7. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number.
  8.  

To install:

  1. Correctly position the spark plug washer.
  2.  
  3. Inspect the spark plug gap. Adjust the gap as needed. See the Gasoline Engine Tune-Up Specifications Chart.
  4.  
  5. Hand start the spark plug in the corresponding cylinder.
  6.  
  7. Tighten the spark plug. See the Torque Specifications Chart.
  8.  
  9. Install the spark plug wire.

    Click image to see an enlarged view

    Fig. OEM spark plug wire identification-4.8L, 5.3L and 6.0L Engines

  10.  

On 4.8L, 5.3L and 6.0L engines there are 2 different Original Equipment Manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows:

The Melco® spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal.

The Delphi® spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal.

The Melco® spark plug wires MUST be used only with the Melco® coils and bracket, like wise the Delphi® spark plug wires MUST be used only with Delphi® coils and bracket. The components are NOT interchangeable.


NOTE
All models were originally equipped with platinum-tip spark plugs which can be used for as-long-as 100,000 miles (161,000 km). This holds true unless internal engine wear or damage and/or improperly operating emissions controls cause plug fouling. If you suspect this, you may wish to remove and inspect the platinum plugs before the recommended mileage. Most platinum plugs should not be cleaned or re-gapped. If you find their condition unsuitable, they should be replaced.

When removing the spark plugs, work on 1 at a time . Don't start by removing the plug wires all at once because unless you number them, they're going to get mixed up. On some models though, it will be more convenient for you to remove all of the wires before you start to work on the plugs. If this is necessary, take a minute before you begin and number the wires with tape before you take them off. The time you spend here will pay off later.

  1. Disconnect the negative battery cable, and if the vehicle has been run recently, allow the engine to thoroughly cool. Attempting to remove plugs from a hot cylinder head could cause the plugs to seize and damage the threads in the cylinder head.
  2.  
  3. Check for access to the plugs on your vehicle. The wheel wells of some vehicles covered by this manual are designed to allow access to the sides of the engine. A rubber cover may be draped over the opening, and it may require removal of 1 or more plastic body snap-fasteners (which are carefully pried loose using a special C-shaped tool) before you can move it aside for clearance. If this is your best access point, raise and support the vehicle safely then remove the front tire and wheel assemblies.
    NOTE
    On some models, the engine cover may be removed to provide additional access to the spark plugs. This will be necessary if you also plan to check the spark plug wires at this time anyway.

  4.  
  5. Carefully twist the spark plug wire boot to loosen it, then pull upward and remove the boot from the plug. Be sure to pull on the boot and not on the wire, otherwise the connector located inside the boot may become separated.
    NOTE
    A spark plug wire removal tool is recommended as it will make removal easier and help prevent damage to the boot and wire assembly.



    Click image to see an enlarged view

    Fig. Disconnect the spark plug wire by pulling on the BOOT, NOT THE WIRE



    Click image to see an enlarged view

    Fig. A spark plug wire removal tool is recommended to prevent wire damage (and to make it easier)

  6.  
  7. Using compressed air (and SAFETY GLASSES), blow any water or debris from the spark plug well to assure that no harmful contaminants are allowed to enter the combustion chamber when the spark plug is removed. If compressed air is not available, use a rag or a brush to clean the area.
    NOTE
    Remove the spark plugs when the engine is cold, if possible, to prevent damage to the threads. If plug removal is difficult, apply a few drops of penetrating oil or silicone spray to the area around the base of the plug, and allow it a few minutes to work.

  8.  
  9. Using a spark plug socket (usually a 5 / 8 in. socket on these engines) that is equipped with a rubber insert to properly hold the plug, turn the spark plug counterclockwise to loosen and remove the spark plug from the bore.
    WARNING
    AVOID the use of a flexible extension on the socket. Use of a flexible extension may allow a shear force to be applied to the plug. A shear force could break the plug off in the cylinder head, leading to costly and frustrating repairs.



    Click image to see an enlarged view

    Fig. Loosen the spark plug using a ratchet and extension . . .



    Click image to see an enlarged view

    Fig. . . . then carefully unthread and remove the plug from the cylinder head

  10.  

To install:

  1. Inspect the spark plug boot for tears or damage. If a damaged boot is found, the spark plug wire must be replaced. As mentioned earlier, this is an excellent time to check each of the spark plug wires for proper resistance and/or for damage.
  2.  
  3. Using a wire feeler gauge, check and adjust the spark plug gap. When using a gauge, the proper size should pass between the electrodes with a slight drag. The next larger size should not be able to pass while the next smaller size should pass freely.
  4.  
  5. Carefully thread the plug into the bore by hand. If resistance is felt before the plug is almost completely threaded, back the plug out and begin threading again. In small, hard to reach areas, an old spark plug wire and boot could be used as a threading tool. The boot will hold the plug while you twist the end of the wire and the wire is supple enough to twist before it would allow the plug to crossthread.
    WARNING
    Do not use the spark plug socket to thread the plugs. Always carefully thread the plug by hand or using an old plug wire to prevent the possibility of crossthreading and damaging the cylinder head bore.

  6.  
  7. Carefully tighten the spark plug. Refer to the Torque Specifications chart for tightening torque.
  8.  
  9. Apply a small amount of silicone dielectric compound to the end of the spark plug lead or inside the spark plug boot to prevent sticking, then install the boot to the spark plug and push until it clicks into place. The click may be felt or heard, then gently pull back on the boot to assure proper contact.
  10.  


NOTE
All models were originally equipped with platinum-tip spark plugs which can be used for as-long-as 100,000 miles (161,000 km). This holds true unless internal engine wear or damage and/or improperly operating emissions controls cause plug fouling. If you suspect this, you may wish to remove and inspect the platinum plugs before the recommended mileage. Most platinum plugs should not be cleaned or re-gapped. If you find their condition unsuitable, they should be replaced.

When removing the spark plugs, work on 1 at a time . Don't start by removing the plug wires all at once because unless you number them, they're going to get mixed up. On some models though, it will be more convenient for you to remove all of the wires before you start to work on the plugs. If this is necessary, take a minute before you begin and number the wires with tape before you take them off. The time you spend here will pay off later.

  1. Disconnect the negative battery cable, and if the vehicle has been run recently, allow the engine to thoroughly cool. Attempting to remove plugs from a hot cylinder head could cause the plugs to seize and damage the threads in the cylinder head.
  2.  
  3. Check for access to the plugs on your vehicle. The wheel wells of some vehicles covered by this manual are designed to allow access to the sides of the engine. A rubber cover may be draped over the opening, and it may require removal of 1 or more plastic body snap-fasteners (which are carefully pried loose using a special C-shaped tool) before you can move it aside for clearance. If this is your best access point, raise and support the vehicle safely then remove the front tire and wheel assemblies.
    NOTE
    On some models, the engine cover may be removed to provide additional access to the spark plugs. This will be necessary if you also plan to check the spark plug wires at this time anyway.

  4.  
  5. Carefully twist the spark plug wire boot to loosen it, then pull upward and remove the boot from the plug. Be sure to pull on the boot and not on the wire, otherwise the connector located inside the boot may become separated.
    NOTE
    A spark plug wire removal tool is recommended as it will make removal easier and help prevent damage to the boot and wire assembly.



    Click image to see an enlarged view

    Fig. Disconnect the spark plug wire by pulling on the BOOT, NOT THE WIRE



    Click image to see an enlarged view

    Fig. A spark plug wire removal tool is recommended to prevent wire damage (and to make it easier)

  6.  
  7. Using compressed air (and SAFETY GLASSES), blow any water or debris from the spark plug well to assure that no harmful contaminants are allowed to enter the combustion chamber when the spark plug is removed. If compressed air is not available, use a rag or a brush to clean the area.
    NOTE
    Remove the spark plugs when the engine is cold, if possible, to prevent damage to the threads. If plug removal is difficult, apply a few drops of penetrating oil or silicone spray to the area around the base of the plug, and allow it a few minutes to work.

  8.  
  9. Using a spark plug socket (usually a 5 / 8 in. socket on these engines) that is equipped with a rubber insert to properly hold the plug, turn the spark plug counterclockwise to loosen and remove the spark plug from the bore.
    WARNING
    AVOID the use of a flexible extension on the socket. Use of a flexible extension may allow a shear force to be applied to the plug. A shear force could break the plug off in the cylinder head, leading to costly and frustrating repairs.



    Click image to see an enlarged view

    Fig. Loosen the spark plug using a ratchet and extension . . .



    Click image to see an enlarged view

    Fig. . . . then carefully unthread and remove the plug from the cylinder head

  10.  

To install:

  1. Inspect the spark plug boot for tears or damage. If a damaged boot is found, the spark plug wire must be replaced. As mentioned earlier, this is an excellent time to check each of the spark plug wires for proper resistance and/or for damage.
  2.  
  3. Using a wire feeler gauge, check and adjust the spark plug gap. When using a gauge, the proper size should pass between the electrodes with a slight drag. The next larger size should not be able to pass while the next smaller size should pass freely.
  4.  
  5. Carefully thread the plug into the bore by hand. If resistance is felt before the plug is almost completely threaded, back the plug out and begin threading again. In small, hard to reach areas, an old spark plug wire and boot could be used as a threading tool. The boot will hold the plug while you twist the end of the wire and the wire is supple enough to twist before it would allow the plug to crossthread.
    WARNING
    Do not use the spark plug socket to thread the plugs. Always carefully thread the plug by hand or using an old plug wire to prevent the possibility of crossthreading and damaging the cylinder head bore.

  6.  
  7. Carefully tighten the spark plug. Refer to the Torque Specifications chart for tightening torque.
  8.  
  9. Apply a small amount of silicone dielectric compound to the end of the spark plug lead or inside the spark plug boot to prevent sticking, then install the boot to the spark plug and push until it clicks into place. The click may be felt or heard, then gently pull back on the boot to assure proper contact.
  10.  

Spark Plug Heat Range



Spark plug heat range is the ability of the plug to dissipate heat. The longer the insulator (or the farther it extends into the engine), the hotter the plug will operate; the shorter the insulator (the closer the electrode is to the block's cooling passages) the cooler it will operate. A plug that absorbs little heat and remains too cool will quickly accumulate deposits of oil and carbon since it is not hot enough to burn them off. This leads to plug fouling and consequently to misfiring. A plug that absorbs too much heat will have no deposits but, due to the excessive heat, the electrodes will burn away quickly and might possibly lead to preignition or other ignition problems. Preignition takes place when plug tips get so hot that they glow sufficiently to ignite the air/fuel mixture before the actual spark occurs. This early ignition will usually cause a pinging during low speeds and heavy loads.

The general rule of thumb for choosing the correct heat range when picking a spark plug is: if most of your driving is long distance, high speed travel, use a colder plug; if most of your driving is stop and go, use a hotter plug. Original equipment plugs are generally a good compromise between the 2 styles and most people never have the need to change their plugs from the factory-recommended heat range.

 
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