GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Express 🢒 Engine 🢒 Engine Controls - 4.8L, 5.3L, and 6.0L 🢒 Spark Plug Wire Replacement

Removal Procedure
  1. Remove the engine cover. Refer to Engine Cover Replacement .

    2. Object Number: 343699 Size: SH
  2. Disconnect the spark plug wire at each spark plug.
    3. • Twist each spark plug wire 1/2 turn.
    • Pull only on the boot in order to remove the wire from each spark plug.
  3. Disconnect the spark plug wire from the ignition coil.
    4. • Twist each spark plug boot 1/2 turn.
    • Pull only on the boot in order to remove the wires from the ignition coil.

Spark Plug Wire Length V8
   • 
Object Number: 340933 Size: SH
  • The Melco® (square design) uses a spark plug wire (1) that is 145 mm (5.70 in) length cable seal to cable seal.
    •    • 
  • The Delphi® (round design) uses a spark plug wire (2) that is 110 mm (4.30 in) length cable seal to cable seal.
    •    • 
    Object Number: 260177 Size: SH
  • There are 2 different manufacturers for the ignition coils. the Melco® (1) (square design), and the Delphi® (2) (round design). These 2 coils use 2 different spark plug wire, and mounting brackets.
    •    • 
    Object Number: 260077 Size: SH
  • Melco® (square design) coil mounting bracket (1).
    •    • 
  • Delphi® (round design) coil mounting bracket (2).

    • Installation Procedure

      Object Number: 343699 Size: SH
    1. Install the spark plug wires at the ignition coil.
    2. Install the spark plug wire to each spark plug.
    3. Inspect the wires for proper installation:
      4. • Push sideways on each boot in order to inspect the seating.
      • Reinstall any loose boot.
    4. Install the engine cover. Refer to Engine Cover Replacement .