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Old 12-28-2005, 01:57 AM   #1
mike270
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Join Date: Nov 2001
Chapter/Region: MWSOC
Vehicle:
2002 2.5RS

Default Plug wire boot seating problem

Just got done changing my spark plugs in my 02RS from the stock champions to some NGK BKR6E11's. Old plugs looked fine to me and the NGK's went in without any problems. When I went to put the plug wires back on though I realized that the rubber boot that used to extend and touch the outside wall of the cylinder head, to keep out dirt and grime I assume, is now 1/4 to 1/2 of an inch away from the head. Its the same way with all 4 plug wires and the car runs perfectly fine. Went out for a drive and pulls good all the way to redline. No misfires or CEL's either.

I changed the plugs (put in the same NGK's) in my dads 2000 Legacy last week and replaced his wires at the same time with OEM wires and his plug wire boot reaches the cylinder head making a decent seal. His plug wires also seem to make a much more positive "click" when they seat compared to my car.

Is this a common thing? I do rallyx so I would imagine this won't be good letting dirt get into the plug wells. Also the wires seem much easier to get out than they were before, somewhat looser.

Sorry if this has been asked, I wasn't able to find anything. Anyone experience something like this or did I somehow manage to do something wrong?
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Old 12-28-2005, 09:45 AM   #2
Hayes
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If the new plugs are the same length as the old then push the wires onto the plugs with more force. Any chance the champ plugs screw-on connector cap remained in the boot?
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Old 12-28-2005, 09:50 AM   #3
mike270
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I'll go look again but when I was trying to get them on I pushed hard enough to deform the boot so that it was contacting the head but it went right back to where it was. I also probably took it off and back 10 times or so to make sure it wasn't getting caught on anything.

I didn't see anything up in the plug boot at all except for the spring-like metal contact although I'm not sure what the connector cap would look like. Comparing the old and the new plugs they appeared to be the same length except for very minor differences between the shapes of the contacts (slightly different arc angles along the contact). I put both old and new plug directly into the plug wire while outside the car to make sure it was seating properly and both plugs went to approximately the same depth on the wire.

I also torqued the plugs with a torque wrench to 15 ft/lbs so that shouldn't be the problem either.

I'm considering buying new plug wires from the dealer? I guess what I may try tonight, unless we can figure something out, is try one of the new plug wires from my dad's Legacy and see if that fits it ok.

In the mean time there couldn't be anything obvious I could have screwed up that wouldn't allow the plug wire to seat properly and possibly do any kind of damage to the engine / head?
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Old 12-28-2005, 02:42 PM   #4
Hayes
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OK Mike: You gave me a clue. Put some silicon or dielectric grease on the outside of the boot. I feel it may be draging too heavy on the sides of the spark plug tube. Let use know what you find. eddie
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Old 12-28-2005, 06:29 PM   #5
mike270
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I'm about to head home to work on it so I will give it a shot. I will try some dielectric grease as well as try the new plug wires from my dads car and see if I can't get anything to work.

Wish me luck! I'll post up my results later.
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Old 12-28-2005, 11:51 PM   #6
mike270
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Well I decided I would try the new plugs from my dads car first before using the dielectric grease. His plug wires fit perfectly in there making a good solid connection and a good seal along the outside of the head. I swapped the plugs between the old and the new and could never get the old plugs to seat, no matter how much force I put into them. So I went and picked up a set from the dealer.

So basically I'm not sure what the problem was. I was going to try to take pictures but I realized I had left my camera at my apartment. The new plugs appear to be the same construction as the old ones except possibly from a different manufacturer since the markings are different on the wires. They only have 2 lengths now instead of 3 different lengths they had before for some reason too making #4 impossible to reach while keeping them in the clips and #1 having a fair bit of slack in the line.

Either way, everything seems to be running good now and fitting properly. Still strange to me that the new plug wires made enough of a difference.
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