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Ignition wire sets

Without the ignition function, even the most efficient engine – whether thermal or linked to a hybrid system, for that matter – would be utterly useless. So our coils, wires and other ignition parts play a crucial role for motorists, and our teams today still take pride in contributing to the Bougicord® brand – world-renowned for over 60 years.

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Ignition
wire sets

The ignition wire set carries the high-voltage energy delivered by the coil to the spark plug to generate the spark required for ignition. Due to its design and the insulating materials used, the ignition wire set protects all electrical and electronic circuits from the high voltage flowing through its wires.

An ignition wire set is subject to a lot of stress. Sudden changes in temperature and humidity, as well as voltage variations, vibrations, corrosive oils and ozone, all contribute to the natural ageing of an ignition wire set. However, it plays a crucial role in ensuring that the vehicle can start and run optimally, hence the need to change it regularly.

Gradually replaced by individual coils, wire sets are no longer used by manufacturers and are no longer fitted to new generations of engines. However, these products are still widely used, and therefore requested by many professionals.

Technologies
Technical information
Frequently asked questions
Technologies

WIRE WOUND TECHNOLOGY

Developed by EFI Automotive, this ignition wire set has a ferromagnetic core around which is wrapped a stainless-steel wire. Two effects combine to ensure excellent interference suppression:

  • Inductive effect: when this wire is crossed by an electric current, a magnetic field is created, and the parasites meet an inductive and ohmic impedance, which results in their attenuation;
  • Resistive effect: the coiled wire acts as a resistor at 5,600 Ω/m.

This invention was patented in 1959. The stainless-steel conductor coiled around a ferromagnetic core conducts the high-voltage current without loss of energy. Interference is absorbed over the entire length of the cable, thus preserving the reception of radio, TV and telephone broadcasts and the vehicle’s on-board electronics. In the frequency ranges reserved for television and radio waves, Bougicord® stands out from most players on the market. The Bougicord® ignition wire technology’ interference suppression is one of its strong points. It has made the brand successful worldwide.

COPPER CORE TECHNOLOGY

This ignition cable has a copper core associated with a point resistor, placed in the shielded caps which are fixed near the spark plugs. Thanks to this resistor, the electrical wave is reflected in the opposite direction (like an echo) and then sent to the vehicle’s ground. This resistor suppresses interference.

Technical information

SYMPTOMS

The following symptoms are often associated with ignition wire set failure:

  • Increased fuel consumption and pollutant emissions;
  • Slow and difficult vehicle start-up in cold and/or wet weather, as the battery is overloaded;
  • Fouling of the spark plugs;
  • Electronic and radio interference;
  • Loss of power and/or acceleration problems;
  • Excessive battery discharge;
  • Fault signal on the dashboard.

DIAGNOSIS PROCEDURE 

First and foremost, you need to visually inspect the ignition wire set to determine if it has a clear fault that can explain its failure. It is strongly recommended to check for the following:

  • The presence of black traces inside the caps;
  • The correct connection of the wires and whether the strands are porous.

It is also possible to test with the motor running, to ensure that there are no abnormal arcs and/or clicks that would indicate a high voltage electricity leak. However, this operation can be dangerous, so be advised: do not touch the strands when the motor is running, as high voltage can cause electrocution.

You can also check the ignition wire set by using a multimeter: place the device’s probes at each end of the wire to check the resistance (according to the manufacturers’ specifications). In France, the standard places the permissible resistance at 5,600 ohms per metre of cable, with a tolerance of about 20%, so the range is between 4,480 and 6,720 Ω/m.

If the previous tests are not conclusive, you must replace your vehicle’s ignition wire set.

CAUSES OF FAILURE

It is possible that the ignition wire set no longer functions due to:

  • Time-related wear due to extreme environmental conditions: temperature changes, humidity, voltage variations, vibrations or corrosive oils (it is recommended to replace them every 70,000 km);
  • Intrusion of rodents that attack the electrical sheaths and insulating padding.

INSTALLATION INSTRUCTIONS

To ensure a quick and efficient installation, you must refer to the following instructions:

  1. Make sure the engine is cold before dismantling the wire set.
  2. Remove and replace one strand at a time, starting with the longest. The numbers usually on the strands correspond to the cylinder number.
  3. Remove all clips and strand separators. Remove the strand by grasping it by the cap and pulling steadily in a rotating motion, without pulling on the cable itself. Do not use pliers, screwdrivers or other tools to pull on the caps.
  4. Clean the spark plug or distributor head with a soft cloth.
  5. Attach the new wire to the spark plug. Reattach the clips and feed the new wire through the separators to the distributor or coil. This is to ensure that you are following the original routing, which keeps the cables away from hot surfaces and/or sharp areas.
  6. Securely attach the caps to the distributor or coil.

Note: On some vehicles a wire connects the coil to the distributor, in this case repeat steps a) to d).

INSTALLATION TIPS

It is important to follow a number of tips when replacing the wire set to avoid mistakes:

  • Make sure you hear the audible “click” when connecting the wire set to the distributor and/or on the coil;
  • Always replace the wire set when the coils, spark plugs or other ignition system components (ignition head, etc.) are changed;
  • Always replace the complete set of wires, not just one strand;
  • To ensure correct ignition, the numbers usually visible on the wires should correspond to the cylinder number and are an additional guarantee that no mistakes have been made during installation.

PREVENTIVE INFORMATION

The above items are provided for information purposes only. They do not replace the advice of a qualified technician or mechanic. We strongly recommend that you consult a professional if you are unsure of what to do. Otherwise, we cannot accept responsibility for any damage to your vehicle.

Frequently asked questions
What symptoms should I look out for?

If you notice that your vehicle has difficulty starting in cold and/or wet weather, has a fault signal on the dashboard or fouling of the spark plugs, then the ignition wire set may be in a critical condition. There is also a good chance that the battery is discharging excessively, and the vehicle is experiencing power loss and/or acceleration problems. Electronics and radio interference are additional symptoms of ignition wire set failure.

How to identify the fault?

Firstly, we strongly advise you to visually check the wire set and its components, i.e., the caps (visible black traces inside), the wires (signs of porosity) as well as the correct connection of the wires.

As a second step, you can perform a test with your motor running, to ensure that there are no abnormal arcs and/or clicks that would indicate a high-voltage electricity leak. However, this operation can be dangerous, so be advised: do not touch the strands when the motor is running, as high voltage can cause electrocution.

You can also check the ignition wire set’s correct functioning by using a multimeter: place the device’s probes at each end of the wire to check the resistance (according to the manufacturers’ specifications). In France, the standard places the permissible resistance at 5 600 ohms per meter of cable, with a tolerance of about 20%, so the range is between 4,480 and 6,720 Ω/m.

If the above tests do not prove conclusive, then it would appear that you will need to replace your vehicle’s ignition wire set.

Why does my ignition wire set need replacing?

There are many reasons why an ignition wire set may be failing. These include time-related wear due to extreme environmental conditions – temperature changes, humidity, voltage variations, vibrations, or corrosive oils (it is usually recommended to replace them every 70,000 km) – as well as the intrusion of rodents that attack the electrical sheaths and insulating padding. Of course, this list is not exhaustive and other reasons can cause the ignition coil to fail.

What are the installation instructions?

We recommend that you follow the following steps to replace your wire set as efficiently as possible and to limit possible mistakes:

  1. Make sure the engine is cold before dismantling the wire set.
  2. Remove and replace one strand at a time, starting with the longest. The numbers usually on the strands correspond to the cylinder number.
  3. Remove all clips and strand separators. Remove the strand by grasping it by the cap and pulling steadily in a rotating motion, without pulling on the cable itself. Do not use pliers, screwdrivers or other tools to pull on the caps.
  4. Clean the spark plug or distributor head with a soft cloth.
  5. Attach the new wire to the spark plug. Reattach the clips and feed the new wire through the separators to the distributor or coil. This is to ensure that you are following the original routing, which keeps the cables away from hot surfaces and/or sharp areas.
  6. Securely attach the caps to the distributor or coil.

On some vehicles a wire connects the coil to the distributor, in this case repeat steps a) to d).

What tips should I use to extend the life of my ignition wire set?

In order to extend your ignition wire set’s durability and as an ignition specialist for over 60 years now, we strongly recommend that you follow the following installation recommendations:

  1. Make sure you hear the audible “click” when connecting the wire set to the distributor and/or on the coil;
  2. Always replace the wire set when the coils, spark plugs or other ignition system components (ignition head, etc.) are changed;
  3. Always replace the complete set of wires, not just one strand.

To ensure correct ignition, the numbers usually on the wires should correspond to the cylinder number and are an additional guarantee that no mistakes have been made during installation.

Other products

Ignition coils

Ignition wire sets