UNIVERSAL WIRE SET ASSEMBLY PROCEDURE
The following procedure will ensure a reliable and professional installation of your wire set.
Measuring The Wires.
1. Your universal wire set comes with the spark plug ends done for you. Starting with the furthest spark plug from the distributor, take one of the longest wires from the set and install it onto the spark plug. Next, route the wire how you would like it, keeping in mind to avoid direct exhaust manifold contact and any sharp edges that may cause abrasion to the wire. Allow any necessary slack in the wire but avoid letting the wires droop.
TIP: As you route your wires, installing loom clips will keep the wires in position for easier measurement and uniform fit with the other leads. Aurora has available proper 8.5mm loom clips in 2 position # 98502, 3 position # 98503, and 4 position # 98504.
2. Where the wire crosses the desired terminal on the distributor cap, place a mark on the wire. This mark will be used later for wire cutting and terminal installation.
Terminal Installation
1. Cut the wire at the mark made during measurement. Carefully strip the wire back 5/8” exposing the center conductor. Do this by cutting through the outer jacket and part way into the center insulation. Pull off the insulation to expose the center conductor. Inspect the conductor for any nicks left from the stripping process. If found, then re-strip. DO NOT use a nicked conductor.
TIP: Most spark plug terminal crimping tools have a wire stripper built in which gives a proper strip. A good crimp tool will have a “W” profile crimp.
2. Fold back the conductor over the wire and install a terminal. Once the terminal is in place, a light squeeze on the terminal wings will hold it in place while the crimp tool is positioned.
TIP: Avoid leaving any “tails” (i.e. the center conductor wire) protruding from the back of the terminal. Trim any excess if necessary.
3. Install the spark plug boot over the terminal. In the case of a brass terminal that requires bending, fit the boot to fit over the straight terminal, first allowing the terminal to protrude approx. 3/16”. Next carefully bend the terminal 90 degrees and reposition the boot as necessary.
TIP: The use of brake cleaner is recommended as a lubricant for installation as it leaves no residue and promotes wire to boot sealing. The use of any oil based lubricants is not recommended as some residues can cause voltage leakage.
Note: When installing the spark plug wires onto the engine, ensure the distributor and spark plug insulators are clean and free from grease/dirt. Failure to do so can result in a misfiring condition later. To ensure positive seating of the wires, a light snap will be heard when the spark plug terminal is properly seated on the spark plug.
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