Originally Posted By: Scott_Tucker
As a professional mechanic, I have seen many engines that misfired because the previous mechanic smeared grease all over the terminals. It does not prevent corrosion on the metal so there is no reason to do it. I use a little on the inside of the spark plug boot to keep out moisture and aid in removal.
+1 The same goes for any electrical connection (in certain scenarios,) because adding too much prevents obtaining a good contact, especially on older coil-pack-type ignition system, IME. The grease will take up all of the space within the boot and push the wire contact up into the boot instead of allowing it to 'click' over the plug end.
I actually experienced this with my old '97 Legacy, and it was my fault! When I first purchased the car I did some routine maintenance, including checking the plugs and checking the wire and coil pack resistances. The previous owner hadn't used any grease, so the wire boots were stuck on the plug to the point where the wire was ruined trying to get it off. Thinking more was better, I filled the boot with grease and put everything back together. The car would throw a misfire code, which continued until I pulled the wires, cleaned out most of the grease with a q-tip and re-installed the wires. The grease, as mentioned above, was pushing the contact up into the boot, allowing for a very bad connection. A pressure was being created inside the boot, too, because no air was able to escape, since there was so much grease. This was probably causing the boot to want to slide back off of the insulator.