Santa FE SM (2001-06) :: Won't Start After Spark Plug Change
Apr 6, 2014
I somehow managed to kill my 04 Santa Fe 3.5 while doing the dreaded spark plug change and looking for pinpointing and rectifying the problem.
A quick rundown of the car... My mom bought her new in late 03, decided to get a BMW X3 a couple of years ago. I bought her with 65k miles. I just recently had the timing belt replaced by a reputable shop at 79k (yes I know I let it go too long.) I just hit 80k and decided it was also time to do the plugs as I had noticed a decrease in performance and gas mileage of late. Other than the recent dip in performance the car has been extremely reliable and has had no previous issues.
I researched as much as I could knowing that the 3.5 isn't the easiest engine to work on. I bought the recommended Champion plugs that came in the car from the factory as well as the oem Hyundai wires. I also replaced the plenum gasket.
I took my time replacing everything but despite my best efforts, I accidentally cracked the plastic on the radiator reaching over to the back bolts on the plenum. Other than that mishap, the only other issues was the #5 plug sticking which finally came loose after some begging and pleading to the car Gods. Unfortunately, my begging and pleading was enough for them to allow the car to start.
After reading a thread on here, I believe the problem is that I removed the TPS sensor to get to the bolts on the EGR valve, I know now that this was a big mistake. I checked and double checked every connector and can not find one that was missed or disconnected. The car would try to start but would not crank over. I was unable to get any OBD2 codes from my code scanner.
I decided to try a TB from a junkyard and swap it on to see if that was the issue. After swapping it on, the car started and ran like crap for about 15 seconds and stalled out. I was however able to pull some codes in this short time.
The codes I received are:
P0102: Mass Airflow Circuit Low Input.
P110 & P1172: ETS Improper Motor Current.
P1192: ETS Limp home - Target Follow Malfunction.
P2127: Throttle Pedal Position Sensor "E" Circuit. Accelerator Position Sensor 2 Voltage Too Low.
I'm not sure if these codes are left over from before I swapped out the TB or not. I reset the codes after I wrote them down and researched them to see if they reappeared but the car will not start again so I can't get the codes to reappear.
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I have a 2011 Escape Limited 3.0l V6 AWD. Did a spark plug change at 115k miles for the first time per dealership recommendation. Got new plugs from dealership.
Was pretty cut and dry to replace. Did not check gap on plugs as was told they are not adjustable per dealership. Put pea sized amount of dialectric grease in the COPs and then fitted the plugs into several times with a little spin to coat evenly. Installed plugs to 11 ft.lbs. and reassembled all components without issue. Installed them one at a time so as to not mix up the coils.
I did break the 90-degree nylon quick disconnect for the fuel line that connects to the fuel supply manifold and had to purchase a new hose assembly. Reinstalled without issue.
Went to start up and engine cranks (hiccup sound) but does not turn over. The sound is weak and not a throaty crank like an engine should give. Check engine light flashes on dash and issues a frequent tone also.
Wondering what the issue is? Are they the wrong plugs? Improperly gapped? Possible the fuel line did not pressurize and there is no fuel getting to the plugs for ignition? Kind of stumped as it was a pretty cut-and-dry replacement (if such a thing is possible).
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