1. Safety First:
* Disconnect the negative battery terminal. This prevents accidental shorts and damage to the electrical system.
* Wear safety glasses. Small metal pieces can fly when removing plugs.
* Work in a well-ventilated area. Engine fumes can be harmful.
2. Preparation:
* Locate the spark plug you need to remove. Consult a repair manual or online diagram for your specific engine to identify the plug's location and access points. The rear plugs are notoriously difficult to reach.
* Gather your tools: You'll need a spark plug socket (typically 5/8" for most Dodge engines of this era), a ratchet, an extension (possibly a swivel extension for better access), and possibly a wobble extension. A spark plug wire puller can also be helpful, and it's a good idea to have a wire brush to clean off corrosion on the plug wire connector. Have some rags handy to clean up any spilled oil or dirt.
3. Accessing the Spark Plug:
This is the most challenging part. Access varies greatly depending on the cylinder's location:
* Front Cylinders (relatively easier): You might be able to reach these from the top, after removing the relevant parts of the engine cover (if present).
* Rear Cylinders (significantly harder): Accessing the rear cylinders often requires more work. You may need to remove:
* Parts of the intake manifold: This is a major undertaking and requires a thorough understanding of your engine's layout. Consult a repair manual for detailed steps. Expect to spend several hours if you have to do this.
* Other components: Depending on the exact location, you might need to remove other components like the air cleaner assembly, various hoses, and potentially other accessories, to get enough clearance.
4. Removing the Spark Plug Wire:
Once you have access, carefully pull off the spark plug wire. A wire puller is strongly recommended to avoid damaging the wire.
5. Removing the Spark Plug:
* Place the spark plug socket securely onto the plug. Use the extension and ratchet to loosen and remove the spark plug. It may be tight, so apply steady pressure. Don't force it; if it's stuck, try some penetrating oil and let it sit for a while.
* Inspect the spark plug: Check its condition for wear, fouling, or damage.
6. Installing the New Spark Plug (if replacing):
* Install the new spark plug by hand, tightening it gently until snug. Then use the spark plug socket and ratchet to tighten it to the manufacturer's specified torque. Over-tightening can damage the spark plug threads. A torque wrench is highly recommended. If you don't have one, carefully tighten it only until it feels snug. Consult your repair manual for the correct torque specification.
* Reconnect the spark plug wire.
7. Reassembly:
Carefully reassemble all components you removed, ensuring everything is correctly positioned. Double-check all connections.
Important Considerations:
* Repair Manual: A repair manual specific to your 1999 Dodge 1500 van is invaluable. It will provide detailed diagrams, torque specifications, and step-by-step instructions.
* Professional Help: If you're not comfortable working on your engine, it's best to take your van to a qualified mechanic. Attempting to remove rear spark plugs without proper knowledge can lead to significant damage.
Remember, this is a general overview. The specifics will vary depending on your engine (3.9L V6 or 5.2L V8) and the specific spark plug you're working on. Always consult a repair manual for detailed instructions.
