Tracker 2000-2004

Spark Plugs

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Inspection



Spark Plug Visual Inspection


Normal operation--Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
 
Carbon Fouled--Dry, fluffy black carbon, or soot caused by the following conditions: rich fuel mixtures; leaking fuel injectors; excessive fuel pressure; restricted air filter element; incorrect combustion.
 
Reduced ignition system voltage output ; weak coils; worn ignition wires; incorrect spark plug gap.
 
Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
 
Deposit Fouling--Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode.
 

Inspection & Gapping



  1. Inspect the terminal post for damage. Inspect for a bent or broken terminal post. Test for a loose terminal post by twisting and pulling the post. The terminal post should NOT move.
  2.  
  3. Inspect the insulator for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator between the terminal post and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.

    Click image to see an enlarged view

    Fig. Spark plug terminal post (1), insulator (2), side electrode (3), and center electrode (4)

  4.  
  5. Inspect the insulator for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes.
  6.  
  7. Inspect for evidence of improper arcing. Measure the gap between the center electrode and the side electrode terminals. An excessively wide electrode gap can prevent correct spark plug operation.
  8.  
  9. Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator to crack.
  10.  
  11. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode.
  12.  
  13. Inspect for a broken or worn side electrode.
  14.  
  15. Inspect for a broken, worn, or loose center electrode by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode reduces the spark intensity. Inspect for bridged electrodes. Deposits on the electrodes reduces or eliminates the gap.
  16.  
  17. Inspect for worn or missing platinum pads on the electrodes, if equipped. Inspect for excessive fouling.
  18.  
  19. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.
  20.  

Removal & Installation



1.6L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the ignition coil electrical connectors.
  4.  
  5. Carefully release the number 1 spark plug wire from the clip on the number 2-3 ignition coil.
  6.  
  7. Remove the 2 bolts from each ignition coil.
  8.  
  9. Remove the number 1 spark plug wire and the number 1-4 ignition coil from the spark plugs.
  10.  
  11. Remove the number 2-3 ignition coil and the number 3 spark plug wire from the spark plugs.
  12.  
  13. Remove the spark plugs from the cylinder head.
  14.  
  15. Inspect the spark plugs for electrode wear, carbon deposits and insulator damage.
  16.  

To install:

  1. Set the spark plug gap to 1.0-1.1 mm (0.039-0.043 in).
  2.  
  3. Install the spark plugs to the cylinder head and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the number 2-3 ignition coil and the number 3 spark plug wire to the spark plugs.
  6.  
  7. Install the number 4 spark plug wire and the number 1-4 ignition coil to the spark plugs.
  8.  
  9. Install the 2 bolts to each ignition coil and tighten to 89 inch lbs. (10 Nm).
  10.  
  11. Carefully secure the number 1 spark plug wire in the clip on the number 2-3 ignition coil.
  12.  
  13. Connect the ignition coil electrical connectors.
  14.  
  15. Connect the negative battery cable.
  16.  

2.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the ignition coil connector from each spark plug coil.
  4.  
  5. Remove the bolt and the coil for each cylinder.
  6.  
  7. Remove the spark plugs from the cylinder head.
  8.  
  9. Inspect the spark plugs for electrode wear, carbon deposits and insulator damage.

    Click image to see an enlarged view

    Fig. Remove the bolt and the ignition coil (1) for each spark plug (2)-2.0L engine

  10.  

To install:

  1. Set the spark plug gap to 1.0-1.1 mm (0.039-0.043 in).
  2.  
  3. Install the spark plugs to the cylinder head and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the ignition coil to each spark plug. Secure with the bolt and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the ignition coil electrical connectors.
  8.  
  9. Connect the negative battery cable.
  10.  

2.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the two fasteners and the ignition coil cover from the valve cover.
  4.  
  5. Disconnect the ignition coil electrical connector.
  6.  
  7. Remove the bolt and the ignition coil for each cylinder.
  8.  
  9. Remove each spark plug from the cylinder head.
  10.  
  11. Inspect the condition of the spark plugs.

    Click image to see an enlarged view

    Fig. Remove the ignition coil cover (2) from the valve cover (1)-2.5L engine

  12.  

To install:

  1. Set the spark plug gap to 1.0-1.1 mm (0.039-0.043 in).
  2.  
  3. Install the spark plugs into the cylinder head and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the ignition coil to each spark plug and secure with the bolt. Tighten the ignition coil bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the ignition coil electrical connectors.
  8.  
  9. Install the ignition coil cover to the valve cover.
  10.  
  11. Secure the ignition coil cover with the two fasteners and tighten to 26 inch lbs. (3 Nm).
  12.  
  13. Connect the negative battery cable.
  14.  

 
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