G6 2005-2007

Spark Plugs

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Inspection & Gapping



Check the plugs for deposits and wear. If they are not going to be replaced, clean the plugs thoroughly. Remember that any kind of deposit will decrease the efficiency of the plug. Plugs can be cleaned on a spark plug cleaning machine, which can sometimes be found in service stations, or you can do an acceptable job of cleaning with a stiff brush. If the plugs are cleaned, the electrodes must be filed flat. Use an ignition points file, not an emery board or the like, which will leave deposits. The electrodes must be filed perfectly flat with sharp edges; rounded edges reduce the spark plug voltage by as much as 50%.

Check spark plug gap before installation. The ground electrode (the L-shaped one connected to the body of the plug) must be parallel to the center electrode and the specified size wire gauge (please refer to the Tune-Up Specifications chart for details) must pass between the electrodes with a slight drag.


NOTE
NEVER adjust the gap on a used platinum type spark plug.

Always check the gap on new plugs as they are not always set correctly at the factory. Do not use a flat feeler gauge when measuring the gap on a used plug, because the reading may be inaccurate. A round-wire type gapping tool is the best way to check the gap. The correct gauge should pass through the electrode gap with a slight drag. If you're in doubt, try one size smaller and one larger. The smaller gauge should go through easily, while the larger one shouldn't go through at all. Wire gapping tools usually have a bending tool attached. Use that to adjust the side electrode until the proper distance is obtained. Absolutely never attempt to bend the center electrode. Also, be careful not to bend the side electrode too far or too often as it may weaken and break off within the engine, requiring removal of the cylinder head to retrieve it.

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Fig. "a1p40"" Inspect the spark plug to determine engine running conditions



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Fig. "S212"" A variety of tools and gauges are needed for spark plug service



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Fig. "S903"" Checking the spark plug gap with a feeler gauge



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Fig. "S904"" Adjusting the spark plug gap



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Fig. "S141"" If the standard plug is in good condition, the electrode may be filed flat-WARNING: do not file platinum plugs

Removal & Installation



2.4L Engine
  1. Remove the ignition coils.
    WARNING
    Make sure that any water and/or debris is blown out of the spark plug holes prior to removing the spark plugs.

  2.  
  3. Remove the spark plugs using a 5 / 8 inch spark plug socket.
    NOTE
    Do not coat spark plug threads with anti-seize compound. If anti-seize compound is used and spark plugs are over-torqued, damage to the cylinder head threads may result.

  4.  
  5. Check spark plug gap for specification, 0.042 inch. (1.06 mm).
  6.  

To install:

  1. Install the spark plugs.
  2.  
  3. Tighten spark plugs to 15 ft. lbs. (20 Nm).
  4.  
  5. Install the ignition coils and tighten mounting bolts to 89 inch. lbs. (10 Nm).
  6.  

3.5L Engine

NOTE
Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug.

  1. If you are replacing the engine left bank spark plugs, remove the air cleaner outlet duct.
  2.  
  3. Remove the spark plug wires from the spark plugs.
  4.  
  5. Remove the spark plugs from the engine.
  6.  

To install:


NOTE
It is important to check the gap of all new and reconditioned spark plugs before installation. Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor engine performance and may even damage the engine.

  1. Gap the spark plugs to the specifications, 0.040 inch. (1.02 mm).
  2.  
  3. Install the spark plugs to the engine.
  4.  
  5. Tighten spark plugs to 11 ft. lbs. (15 Nm).
    NOTE
    For new cylinder head tighten plugs to 15 ft. lbs. (20 Nm).

  6.  
  7. Install the spark plug wires to the spark plugs.
  8.  

3.6L Engine

NOTE
Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug threads to seize, causing damage to cylinder head threads.

  1. Remove ignition coils.
  2.  
  3. Use compressed air in order to remove debris from the spark plug cavity.
  4.  
  5. Remove the spark plugs.
  6.  

To install:

  1. Ensure that the spark plug gap is equivalent to the spark plug gap specification. 0.043 inch. (1.10 mm).
    NOTE
    Be sure that the spark plug threads smoothly into the cylinder head and the spark plug is fully seated. Use a thread chaser, if necessary, to clean threads in the cylinder head. Cross-threading or failing to fully seat the spark plug can cause overheating of the plug, exhaust blow-by, or thread damage.

  2.  
  3. Install the spark plugs.
  4.  
  5. Tighten spark plugs to 15 ft. lbs. (20 Nm).
  6.  
  7. Install ignition coils and tighten mounting bolts to 89 inch. lbs. (10 Nm).
  8.  

3.9L Engine

NOTE
Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug.

  1. Remove the air cleaner outlet duct, if required.
  2.  
  3. Remove the intake manifold cover, if required.
  4.  
  5. Remove the left side spark plug wires from the spark plugs.
  6.  
  7. Remove the right side spark plug wires from the spark plugs.
  8.  
  9. Remove the spark plugs.
  10.  

To install:

  1. Ensure that the spark plug gap is equivalent to the spark plug gap specification. 0.040 inch. (1.02 mm).
  2.  
  3. Install the spark plugs.
  4.  
  5. Tighten spark plugs to 11 ft. lbs. (15 Nm).
  6.  
  7. Install the right side spark plug wires to the spark plugs,
  8.  
  9. Install the left side spark plug wires to the spark plugs,
  10.  
  11. Install the intake manifold cover, if required.
  12.  
  13. Install the air cleaner outlet duct, if required.
  14.  

 
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