Malibu, Malibu MAXX 2006-2008

Spark Plug Wires

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Inspection & Testing



3.5L & 3.9L Engines

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation.

  1. Refer to the list below for items to be inspected.
    1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing.
    2.  
    3. Inspect each wire for any signs of cracks or splits in the wire.
    4.  

  2.  
  3. Inspect each boot for the following conditions:

    Tearing
     
    Piercing
     
    Arcing
     
    Carbon Tracking
     
    Corroded terminal
     

  4.  
  5. If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal both the wire and the component connected to the wire should be replaced.
  6.  

Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.

  2.  
  3. Remove the intake manifold cover, if required.
  4.  
  5. Disconnect the left side spark plug wires from the spark plugs.
  6.  
  7. Disconnect the left side spark plug wires from the ignition coil.
  8.  
  9. Remove the spark plug wire clips from the Manifold Absolute Pressure (MAP) sensor bracket and the heater inlet and outlet pipe tab.
  10.  
  11. Remove the spark plug wire assembly.
  12.  
  13. If replacing only one plug wire, open the retaining clips and remove the appropriate spark plug wire.
  14.  
  15. Disconnect the right side spark plug wires from the spark plugs.
  16.  
  17. Disconnect the right side spark plugs from the ignition coils.
  18.  
  19. Remove the spark plug wire assembly.
  20.  
  21. If replacing only one plug wire, open the retaining clip and remove the appropriate spark plug wire.
  22.  

To install:

  1. Install the spark plug wire assembly.
  2.  
  3. Connect the right side spark plugs to the ignition coils.
  4.  
  5. Connect the right side spark plug wires to the spark plugs.
  6.  
  7. If replacing only one plug wire, open the retaining clip and install the appropriate spark plug wire.
  8.  
  9. Install the spark plug wire assembly.
  10.  
  11. Connect the left side spark plug wires to the spark plugs.
  12.  
  13. Connect the left side spark plug wires to the ignition coil.
  14.  
  15. Install the spark plug wire clips to the MAP sensor bracket and the heater inlet and outlet pipe tab.
  16.  
  17. If replacing only one plug wire, open the retaining clips and install the appropriate spark plug wire.
  18.  
  19. Install the intake manifold cover, if required.
  20.  

3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.

  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Disconnect the left side spark plug wires from the spark plugs.
  6.  
  7. Disconnect the left side spark plug wires from the ignition coil.
  8.  
  9. If replacing only one plug wire, open the retaining clips and remove the spark plug wire.
  10.  
  11. Remove the left side spark plug wire clips from the intake manifold bracket and heater inlet and outlet pipe.
  12.  
  13. Remove the spark plug wire assembly.
  14.  
  15. Disconnect the right side spark plug wires from the right side spark plugs.
  16.  
  17. Disconnect the left side spark plug wires from the ignition coil.
  18.  
  19. If replacing only one plug wire, open the retaining clips and remove the spark plug wire.
  20.  
  21. Remove the right side spark plug wire clip from the ignition coil bracket.
  22.  
  23. Remove the spark plug wire assembly.
  24.  

To install:

  1. Install the spark plug wire assembly.
  2.  
  3. Install the right side spark plug wire clip at the ignition coil bracket.
  4.  
  5. If only one plug wire was replaced, install the plug wire and close the retaining clip.
  6.  
  7. Connect the right side spark plug wires to the ignition coil.
  8.  
  9. Connect the right side spark plug wires to the right side spark plugs.
  10.  
  11. Install the spark plug wire assembly.
  12.  
  13. Install the left side spark plug wire clips at the intake manifold bracket and heater inlet and outlet pipe.
  14.  
  15. If only one plug wire was replaced, install the plug wire and close the retaining clips.
  16.  
  17. Connect the left side spark plug wires to the ignition coil.
  18.  
  19. Connect the left side spark plug wires to the spark plugs.
  20.  
  21. Install the intake manifold cover.
  22.  

 
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