Tucson 2006-2008

Spark Plug Wires

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Inspection & Testing



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. 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.  
  5. Inspect each boot for the following conditions:

    Tearing
     
    Piercing
     
    Arcing
     
    Carbon tracking
     
    Corroded terminal end
     

  6.  
  7. 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.
  8.  

Removal & Installation



2.0L Engine

Specific to:

Hyundai Tucson 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    When removing the spark plug wire, pull on the spark plug wire boot (not the wire) to prevent damage to the wire.

  2.  
  3. Remove the spark plug wires from the spark plugs using the following steps:
    NOTE
    Note the position of the spark plug wires before removing the wires and place removed wires in cylinder order for ease of installation later.

    1. Twist the spark plug boot 1 / 2 turn before removing the boot.
    2.  
    3. Remove the spark plug wire (A) from the spark plug (B).
    4.  

  4.  
  5. Remove the spark plug wire from the ignition coil.
  6.  
  7. Remove the spark plug wire from any retaining clips.
  8.  
  9. Repeat the above steps to remove all the spark plug wires from the engine.

    Click image to see an enlarged view

    Fig. Remove the spark plug wire (A) from the spark plug (B)-2.0L engine

  10.  

To install:

  1. When replacing the spark plug wires, transfer any of the following:

    Boot heat shields
     
    Spark plug wire conduit
     
    Spark plug wire retaining clips
     

  2.  
  3. Position the correct length of spark plug wire to each cylinder.
  4.  
  5. Install the spark plug wire into the correct retaining clips.
  6.  
  7. Install the spark plug wires to the ignition coil in the proper position.
  8.  
  9. Install the spark plug wires to the spark plugs.
  10.  

2.7L Engine

Specific to:

Hyundai Tucson 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Disconnect the Variable Intake System (VIS) actuator connectors and the fuel injector connectors.
  6.  
  7. Remove the accelerator cable.
  8.  
  9. Remove the surge tank sub assembly.
    WARNING
    When removing the spark plug wire, pull on the spark plug wire boot (not the wire) to prevent damage to the wire.



    Click image to see an enlarged view

    Fig. Remove the surge tank sub assembly-2.7L engine

  10.  
  11. Remove the spark plug wires from the spark plugs using the following steps:
    NOTE
    Note the position of the spark plug wires before removing the wires and place removed wires in cylinder order for ease of installation later.

    1. Twist the spark plug boot 1 / 2 turn before removing the boot.
    2.  
    3. Remove the spark plug wire from the spark plug.
    4.  

  12.  
  13. Remove the spark plug wire from the ignition coil.
  14.  
  15. Remove the spark plug wire from any retaining clips.
  16.  
  17. Repeat the above steps to remove all the spark plug wires from the engine.
  18.  

To install:

  1. When replacing the spark plug wires, transfer any of the following:

    Boot heat shields
     
    Spark plug wire conduit
     
    Spark plug wire retaining clips
     

  2.  
  3. Position the correct length of spark plug wire to each cylinder.
  4.  
  5. Install the spark plug wire into the correct retaining clips.
  6.  
  7. Install the spark plug wires to the ignition coil in the proper position.
  8.  
  9. Install the spark plug wires to the spark plugs.
  10.  
  11. Install surge tank sub assembly.
  12.  
  13. Install the accelerator cable.
  14.  
  15. Connect the Variable Intake System (VIS) actuator connectors and the fuel injector connectors.
  16.  
  17. Install the engine cover.
  18.  

 
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