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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1257 (ENGINE CONTROLS AND FUEL - 4.3L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSSPARK PLUG WIRE REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page is about a different car, the 2008 GMC Sierra and 2008 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine.
    Fig 1: View Of Spark Plug Wire Separators & Boots
    GM1876924Courtesy of GENERAL MOTORS CORP.
  1. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots.
  2. Install the appropriate spark plug wire(s)
  3. Close the spark plug wire separators (1).
  4. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar).
    5. Fig 2: View Of Spark Plug Wires
    GM1876875Courtesy of GENERAL MOTORS CORP.
  5. Install the appropriate spark plug wire boot(s) (1, 2) to the ignition coil.
    6. Fig 3: View Of Proper Spark Plug Routing
    GM1876925Courtesy of GENERAL MOTORS CORP.
  6. Inspect the spark plug wires for proper routing (1, 2, 3, 4, 5, 6) and installation.
    1. Push sideways on each boot in order to inspect the seating.
    2. Reinstall any loose boot.
    3. Any time the spark plug wire or boot are installed on the spark plug, new dielectric grease needs to be applied inside the boot.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.