Hyundai Coupes/Sedans 1994-1998 Repair Guide

Spark Plug Wires

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See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Proper routing of spark plug wires on 4-cylinder engines is critical to a smooth running engine



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Fig. Fig. 2: Spark plug wires should be routed so that they do not touch or cross each other at less than a 45 degree angle



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Fig. Fig. 3: Label each spark plug wire with its corresponding cylinder number ...



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Fig. Fig. 4: ... also, label each terminal on the distributor cap

REMOVAL & INSTALLATION



  1. Label each spark plug wire and make a note of its routing.
  2.  

Don't rely on wiring diagrams or sketches for spark plug wire routing. Improper arrangement of spark plug wires will induce voltage between wires, causing misfiring and surging. Be careful to arrange spark plug wires properly.

  1. Starting with the longest wire, disconnect the spark plug wire from the spark plug and then from the distributor or coil pack.
  2.  

To install:
  1. If replacing the spark plug wires, match the old wire with an appropriately sized wire in the new set.
  2.  
  3. Lubricate the boots and terminals with dielectric grease and install the wire on the distributor or coil pack. Make sure the wire snaps into place.
  4.  
  5. Route the wire in the exact path as the original and connect the wire to the spark plug.
  6.  
  7. Repeat the process for each remaining wire, working from the longest wire to the shortest.
  8.  

TESTING



See Figures 5 and 6



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Fig. Fig. 5: Checking plug wire resistance through the distributor cap with an ohmmeter



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Fig. Fig. 6: Checking individual plug wire resistance with a digital ohmmeter

Spark plug wires should be inspected at every tune-up/safety inspection. Visually check the spark plug wires for burns, cuts or breaks in the insulation. Check the boots and the nipples on the distributor cap and/or coil pack. Replace any damaged wiring.

Every 30,000 miles (48,000 km) or 30 months, the resistance of the wires should be checked with an ohmmeter. Wires with excessive resistance will cause misfiring, and may make the engine difficult to start in damp weather.

To check resistance on distributor equipped engines, disconnect the distributor cap from the distributor and disconnect the spark plug wire from spark plug. Using a digital ohmmeter, measure the resistance between the terminal inside the distributor cap and the terminal at the spark plug end of the wire. Resistance should be LESS than 10,000 ohms per foot of wire. If resistance is not within specification, replace the wire.

If one spark plug wire is found to be out of specification, it is a good idea to replace the entire set.

To check resistance on distributorless ignition engines, disconnect the spark plug wire from both the coil pack and the spark plug. Using a digital ohmmeter, measure the resistance between the coil end terminal and the spark plug end terminal. Resistance should be LESS than 10,000 ohms per foot of wire. If resistance is not within specification, replace the wire.

 
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