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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 4 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 4.3L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSSPARK PLUG WIRE REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page is about a different variant/trim than selected.
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: Identifying Spark Plug Wire Boots & Plugs (Right Side)
    GM1950008Courtesy 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 of the spark plug wire boots.
  2. If required, install the appropriate right side spark plug wire(s).
  3. Close the spark plug wire separators (2).
  4. Install the appropriate right side spark plug wire boot(s) (1) to the spark plug(s).
    5. Fig 2: Identifying Spark Plug Wire Boots & Plugs (Left Side)
    GM1950007Courtesy of GENERAL MOTORS CORP.
  5. If required, install the appropriate left side spark plug wire(s).
  6. Close the spark plug wire separators (1).
  7. Install the appropriate left side spark plug wire boot(s) (2) to the spark plug(s).
    8. Fig 3: Removing/Installing Spark Plug Wire Boots
    GM1950006Courtesy of GENERAL MOTORS CORP.
  8. Install the appropriate bank 1 spark plug wire boot(s) (1), or bank 2 spark plug wires boot(s) (2) to the ignition coil.
    9. Fig 4: Identifying Spark Plug Wire Inspection Points
    GM1950009Courtesy of GENERAL MOTORS CORP.
  9. 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 is installed on the spark plug, new dielectric grease needs to be applied inside the boot.
  10. Install the engine cover. Refer to Engine Cover Replacement .
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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.