Ignition Leads 2013 Introduction Standard Motor Products Europe (SMPE) is one of Europe’s leading manufacturers of high quality, proprietary and private brand ignition leads and sets for the automotive aftermarket. Based in England, SMPE were one of the first specialist aftermarket ignition lead manufacturers in Europe; as such SMPE currently supply many of the major names in the European aftermarket. The extensive KERR NELSON HighVolt product offering is designed, manufactured and supplied utilising state of the art systems and processes. It is this commitment to employing the highest quality systems and processes, which has resulted in SMPE becoming one of the first specialist aftermarket ignition lead suppliers to be awarded ISO9001 ccreditation. A key requirement of ISO9001 is continuous improvement. This philosophy has been embraced in all aspects of SMPE’s business. Evidence of SMPE’s commitment to continuous improvement can be seen in the just-in-time manufacturing process and flexible production setup allowing efficient assembly for a large variety of part numbers to satisfy market requirements. SMPE are focused on new product development driven from a European vehicle parc database and industry leading applications cataloguing. The current KERR NELSON HighVolt programme of ignition leads provides the latest development of a range that has continually evolved to keep pace with the changing demands of both vehicle technology and customer requirements. By embracing the philosophy of continued product improvement SMPE is able to offer: Respected Brand Comprehensive Product Offering Premium Quality Product Outstanding Availability Excellent Technical Support Guaranteed Customer Satisfaction The Role of Ignition Leads in a Conventional Ignition System The primary function of the ignition system is to initiate the firing of the air/fuel mixture in a spark ignition engine. The main components of the system are the coil, distributor, ignition leads and the spark plugs. The ignition leads are the key components in linking all the other elements together. Their function is to transfer a high voltage charge from the coil to the distributor and then to the spark plugs. The ignition lead set comprises of a lead that runs from the coil to the distributor and leads which run from the distributor to each of the spark plugs as illustrated above. Terminals and boots are fitted to both ends, which are tailored to each individual application. The traditional mechanical ignition system as depicted in the above illustration has now largely evolved into the more common solid state electronic ignition. These are known as Distributorless Ignition Systems (D.I.S.) and are coil-less ignition systems, distributing the firing spark via a single or series of power packs with only one lead per cylinder without separate coil lead. In addition, some manufacturers (for example some Ford applications) employ a semi- direct method of ignition. This combines the technologies of both the direct and indirect systems, used for the ever demanding compromise of cost versus functional reliability and spatial constraints. Functional Requirements of Ignition Leads Transmit in excess of 35 000 Volts Suppress radio frequency interference Eliminate voltage losses through the ignition system Resist harsh environmental operating conditions Provide secure electrical contact Meet individual vehicles fitment (boot design and lead lengths) KERR NELSON HighVolt Lead Technologies Wirewound core technology (Reactive cable) The cable is made up of a carbon-coated fibreglass core enclosed in stainless steel windings. Engineered to meet or exceed SAE specifications for radio frequency interference, suppression comes from a magnetic field created when current crosses the steel winding. This type of cable is mainly used by French and Japanese vehicle manufacturers as well as Saab and Volvo. Glass Fibre Core Silicone inner insulation EPDM/Silicone distributor boot Glass-fibre braid Dedicated zinc plated steel spark plug terminal Silicone outer jacket Dedicated brass distributor terminals Silicone spark plug boot Stainless Steel windings Resistive core technology This is the simplest and most robust of the cables used and works by providing resistance along the length of the cable. This type of technology is typically used by American, British and Asian vehicle manufacturers. Copper core technology This consists of copper wire with negligible resistance combined with an in- built resistance of a pre-determined value in order to generate the required suppression. The complex nature of copper core componentry makes this technology significantly more expensive than the other technology types available. This type of cable is predominantly used by German manufacturers. Impregnated Carbon Glass Fibre Core Tin plated copper core Silicone inner insulation Encapsulated resistor Glass-fibre braid Stainless Steel casing Silicone outer jacket Dedicated spark plug connector Silicone spark plug boot Dedicated distributor connector EPDM/Silicone distributor boot Dedicated zinc plated steel spark plug terminal Dedicated brass distributor terminals Benefits of Fitting KERR NELSON HighVolt To ensure the optimum performance all our lead sets are specifically tailored to each individual make and model of vehicle. We specify the highest grade and quality materials possible, which meets or even exceeds the OEM specification, specifying the same cable technologies in the KERR NELSON HighVolt brand as offered by the original manufacturers. All cables comprise of double silicone insulation and meet the highest standards set out by ISO3808, which ensure unsurpassed insulating properties against their harsh operating conditions. Right first time fitment Improved starting performance Elimination of engine misfires Maximised engine power output Protection of sensitive engine components (catalytic converter, lambda sensors etc) Improved fuel consumption Reduced exhaust emissions Improved radio reception Safeguards on-board electronics Why do ignition leads need changing ? Over time the cable deteriorates due to the harsh environmental conditions to which it is subjected. Damage to the ignition leads can usually not be seen as the energy is lost through microscopic cracks. Also, the sealing ability of the boots deteriorates and the terminals oxidise. These imperfections can culminate to produce a substantial dip in performance and reliability of the vehicle. How do you know when they need changing ? Ignition leads are consumable products which need to be inspected systematically on a regular basis. There are several noticeable problems which may suggest that the ignition leads need replacing, these include: • Difficulties when starting the engine, especially in damp weather • Increased fuel consumption • Misfire, especially when the engine is under load (accelerating) • Excess radio interference Failure to replace a faulty ignition lead may, through a loss of interference suppression, cause problems with on board electronic equipment, such as radio, airbags, ABS, alarm, etc. Furthermore, an engine misfire may cause irreparable damage to the catalytic converter and lambda sensors, which will ultimately causes excessive environmental pollution and increased repair costs. Cross Reference Section Extensive cross reference section is available for online search via the SMPE website : www.smpeurope.com Click on CATALOGUE – HighVolt – SEARCH BY OE/COMPETITOR NUMBER ALFA ROMEO 33 (905) - 33 (907A) ALTERNATIVE LEADSET 33 (905) 1.2 (905.A) 33 Kw:50 PS:68 4Cyl 8v Front Wheel Drive Hatch- AR 30585 06/1983-12/1989 OEF071 Wirewound Core Cable, 5 Leads back, 1186cc 1.3 33 Kw:58 PS:79 4Cyl 8v Front Wheel Drive Hatchback, AR 30502 05/1983-12/1989 OEF271 Resistive Cable, 5 Leads 1351cc 1.3 (905.A1A, 905.A1C, 905.A1D, 905.A1F, 905.A1H) 33 Kw:63 AR 30168; AR 10/1984-12/1989 OEF071 Wirewound Core Cable, 5 Leads PS:86 4Cyl 8v Front Wheel Drive Hatchback, 1351cc 30587 1.3 (905.A1B, 905.A1C, 905.A1G) 33 Kw:55 PS:75 4Cyl 8v AR 30502; AR 06/1983-12/1989 OEF271 Resistive Cable, 5 Leads Front Wheel Drive Hatchback, 1351cc 30586 1.3 i.e. 33 Kw:66 PS:90 4Cyl 8v Front Wheel Drive Hatchback, AR 30168 05/1983-12/1989 OEF071 Wirewound Core Cable, 5 Leads 1351cc 1.5 33 Kw:70 PS:95 4Cyl 8v Front Wheel Drive Hatchback, AR 30182 05/1983-12/1993 OEF271 Resistive Cable, 5 Leads 1490cc 1.5 (905.A2) 33 Kw:75 PS:102 4Cyl 8v Front Wheel Drive AR 30588 07/1986-12/1989 OEF071 Wirewound Core Cable, 5 Leads Hatchback, 1490cc 1.5 (905.A2A) 33 Kw:62 PS:84 4Cyl 8v Front Wheel Drive AR 30143; AR 06/1983-12/1985 OEF271 Resistive Cable, 5 Leads Hatchback, 1490cc 30504 1.5 (905.A2G) 33 Kw:66 PS:90 4Cyl 8v Front Wheel Drive AR 30520 06/1983-12/1986 OEF271 Resistive Cable, 5 Leads Hatchback, 1490cc 1.5 4x4 (905.A2) 33 Kw:62 PS:84 4Cyl 8v All-wheel Drive AR 30504 11/1983-12/1984 OEF271 Resistive Cable, 5 Leads Hatchback, 1490cc 1.5 4x4 (905.A2) 33 Kw:75 PS:102 4Cyl 8v All-wheel Drive AR 30588 07/1986-12/1989 OEF071 Wirewound Core Cable, 5 Leads Hatchback, 1490cc 1.5 4x4 (905.A2A) 33 Kw:70 PS:95 4Cyl 8v All-wheel Drive AR 30514 01/1984-12/1989 OEF271 Resistive Cable, 5 Leads Hatchback, 1490cc 1.5 4x4 (905.A2F) 33 Kw:66 PS:90 4Cyl 8v All-wheel Drive AR 30520 01/1985-09/1986 OEF271 Resistive Cable, 5 Leads Hatchback, 1490cc 1.5 4x4 (905.A2M, 905.A2T) 33 Kw:77 PS:105 4Cyl 8v All-wheel AR 30146; AR 09/1986-12/1989 OEF071 Wirewound Core Cable, 5 Leads Drive Hatchback, 1490cc 30588 1.5 QV (905.A2N, 905.A2V) 33 Kw:77 PS:105 4Cyl 8v Front AR 30146; AR 06/1984-12/1989 OEF071 Wirewound Core Cable, 5 Leads Wheel Drive Hatchback, 1490cc 30508; AR 30588 1.7 33 Kw:87 PS:118 4Cyl 8v Front Wheel Drive Hatchback, AR 30550 01/1986-12/1989 OEF071 Wirewound Core Cable, 5 Leads 1712cc 1.7 33 Kw:95 PS:129 4Cyl 8v Front Wheel Drive Hatchback, AR 30550 01/1986-12/1989 OEF071 Wirewound Core Cable, 5 Leads 1712cc 1.7 i.e.