How to Crimp Spark Plug Wires
Spark plugs play a significant role in the smooth running of engines. However, spark plug wires often require replacement due to damage or wear and tear. You may get a pre-terminated spark plug wire kit for replacement, but they may not be the ideal choice if the wire is of ideal length or doesn’t match your engine specification. Alternatively, you may make your own by crimping spark plug terminals onto the spark plug wires.
Overall, crimping spark plug wires is not a complicated process. However, you have to pay attention because an improperly terminated spark plug wire may result in some inefficiencies, such as poor gas mileage and increased emissions. For this reason, this post outlines a step-by-step process for going about this process.
A Guide to Crimping Spark Plug Wires
Step 1: Gather the necessary tools
The first step entails gathering all the necessary tools and components for the crimping process. They include:
- A ratchet crimping tool- you should choose a crimper specifically designed for spark plug terminals. The iCrimp LY-2048 Ratchet Spark Plug Wire Crimper is an ideal example of such a crimper.
- A wire stripper- is used to strip the insulation from the end of the wire.
- A wire cutter- it helps cut the wire to the desired length.
- Spark plug wires- choose quality wire with the proper gauge for your engine.
- Replacement spark plug terminals should match the gauge of the wire you’ll use.
- Spark plug boots
Step 2: Prepare the wire
Preparation may differ depending on whether the wire is already connected to the engine or if you intend to make a new crimp connection on both ends from scratch. If the spark plug wire is connected to the car, consider disconnecting the battery’s negative terminal before you start doing anything else. If you’re working with a new wire, determine the length needed and use a wire cutter to make a clean cut.
Then, proceed and carefully strip about a half inch of the insulation from the end(s) of the spark plug wire. However, the amount of insulation stripped often depends on whether it’s a dual crimp wire or the typical wire you fold back to the conductor.
Stripping creates room for inserting the spark plug terminals. Slide the terminals onto the ends of the spark plug wires and align them with the conductor.
Step 3: Crimp the terminals
The next step is placing the terminal and wire assembly into the right crimp slot of your crimping tool. Squeeze the handles of the crimping tool until you hear a clicking sound or until that particular crimping cycle is complete. Crimping pressure may vary depending on the crimping tool you choose. Also, if you’re working with a double-crimp wire terminal, you should crimp the silicone jacket and conductor separately.
Step 4: Inspect the quality of crimps
You should visually inspect the crimp to ensure you’ve created a quality crimp connection. Ensure the terminal is well secured to the spark plug wire. You can use the pull-test method to ensure your terminals are well-secured and tight. Alternatively, you can perform a standard continuity and resistance check.
Step 5: Insert spark plug boots
You should then insert spark plug boots on the crimp joints you created. Apply a bit of grease on the tip of the spark plug boot and the outer part of the terminal. The grease helps you to insert the spark plug boots easily.
Step 6: Repeat steps 3 to 5 for other wire ends
Read more: Application of Battery Cable Lugs
Bottom line
Following the above steps, you can easily and successfully crimp spark plug wires. However, having the right tools and components can give you an edge in crimping. Therefore, you can have quality and secure crimp connections that make your spark plugs run efficiently and for a long time.
iCrimp is one of the most reliable platforms for quality and affordable crimping tools, including spark plug wire crimpers. Our crimping tools feature ergonomic designs and quality builds and are enhanced with efficient crimping mechanisms for better performance and results.
References
