Mitsubishi Pick-ups and Montero 1983-1995 Repair Guide

Spark Plug Wires



See Figure 1

At every tune-up inspection, visually inspect the spark plug cables for burns cuts, or breaks in the insulation. Check the boots and the nipples on the distributor cap and coil. Replace any damaged wiring.

Every 50,000 miles (80,000 km) or 60 months, replace the spark plug wires or at the least check the resistance of the wires with an ohmmeter. Wires with excessive resistance will cause misfiring, and may make the engine difficult to start in damp weather.

Click image to see an enlarged view

Fig. Fig. 1: Some factory spark plug wires have numbers already printed on them (arrow): in this case labeling is not necessary

To check resistance, remove the distributor cap, leaving the wires attached. Connect one lead of an ohmmeter to an electrode within the cap; connect the other lead to the corresponding spark plug terminal (remove it from the plug for this test). Replace any wire which shows a resistance over 30,000 ohms. Test the high tension lead from the coil by connecting the ohmmeter between the center contact in the distributor cap and either of the primary terminals of the coil. If resistance is more than 25,000 ohms, remove the cable from the coil and check the resistance of the cable alone. Anything over 15,000 ohms is cause for replacement. It should be remembered that resistance is also a function of length; the longer the cable, the greater the resistance. Thus, if the cables on your truck are longer than the factory originals, resistance will be higher, quite possibly outside these limits.

When installing new cables, replace them one at a time to avoid mix-ups. Start by replacing the longest one first. Install the boot firmly over the spark plug. Route the wire over the same path as the original. Insert the nipple firmly into the tower on the cap or the coil. Check the spark plug cable routing and always make sure the plug wires are in the correct plug wire bracket.