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This rerouting procedure should be performed before any other misfire, surge, or spark knock repairs are attempted. Remove coil wire from distributor cap tower terminal. Remove coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip along the lower side of the right valve cover.
Install 3 one wire clips along the top and front of the valve cover. Use the valve cover retaining bolt studs Fig 1. Route the coil wire starting from the ignition coil and working toward the distributor. Any excess wire should end up at the distributor end.
Install the coil wire into the one wire clips. This may be easier to perform while the coil wire is loose from the valve cover and before the one-wire clips are attached to the valve cover studs. Cut the ignition wire convolute into three lengths 8", 4", and 3. Slit and install the three sections of convolute onto the coil wire between the clips. Install the 8" and the 4" sections along the top side of the right valve cover.
Route the distributor end of the coil wire down and behind the intake manifold in front of the oil pressure switch.
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The coil wire must be a minimum of 1" away from any other ignition wires. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil tower terminal. Use the original piece of coil wire convolute to protect the wire against chafing by components at the rear of the engine.
Remove the 8 plug wire from the distributor tower terminal. Remove the 8 plug wire from the five-wire clip at the lower rear of the valve cover. Route the 8 plug wire over the rear quarter of the right valve cover Fig 3. Reposition the original piece of plug wire convolute to prevent the wire from chafing at the right valve cover and with other engine components.
Secure the 8 plug wire and convolute in place with the hose to wire clip. The small end of the clip supports the convolute. The large end of the clip attaches to the heater hose. Make sure the 8 plug wire is secure and away from the 4 plug wire. Make certain it will not fall to contact the cylinder head or exhaust components. Install the 8 plug wire into its distributor cap terminal. Remove the 4 cylinder plug wire from the distributor cap terminal.
At the center of the lower side of the right valve cover is three-wire clip. Keep the 2 and 4 plug wires from crossing each other at this clip. Position the 2 plug wire in the top wire slot and the 4 wire in the bottom wire slot. Leave the middle slot empty Fig 5. Keep the plug wires from crossing and chafing each other at the five-wire clip found at the right rear lower side of the valve cover.
Position the 4 plug wire in a slot that will space it farthest away from the 8 plug wire Fig 6. Remove any slack in the 4 plug wire between the three-wire and the five-wire clips.
Earlier model five-wire clips look slightly different but the same wiring layout applies. Route the 4 plug wire behind the transmission dipstick tube and heater hoses. Make sure that the 4 plug wire is at least one inch away from the 8 wire. Install the 4 Plug wire to its distributor cap terminal Fig 7.
This is the original wire routing on and earlier models. For models, the 7 plug wire was shortened. Reroute the 7 wire so that it crosses the distributor cap and leaves the cap between the 6 and 5 tower terminals Fig 9.
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Make sure the 7 plug wire is at least one inch away from the 5 wire. Remove the 5 plug wire from the five-wire clip found at the lower rear of the left valve cover. Route the 5 plug wire over the left valve cover and in front of the breather tube elbow.
Position the original convolute from the 5 wire to prevent chafing against the valve cover and any engine components.
Secure the small end of the hose to wire clip over the convolute. Secure the large end of the hose to wire clip to the breather hose.
Make sure the 5 plug wire is secure and away from the 7 plug wire. Reimbursable within the terms of the warranty.