Make spark plug wires with your own hands. Zero resistance wires

Purpose of high-voltage wires, general information. The main task of high-voltage wires is to transmit electrical impulses from the ignition coil to the spark plugs. Therefore they must:

withstand high voltage (up to 40,000 V), transmit pulses with low losses,
ensure a minimum of interference for radio-electronic equipment,
have good insulation to prevent current leakage,
maintain their properties over a wide temperature range - from minus 30°C in winter to plus 100°C or more when the engine is running in summer.

To transmit a high-voltage pulse with minimal losses, it is desirable to reduce the electrical resistance of the wire. Therefore, many years ago, wires with a copper conductor were successfully used. But with the beginning of the widespread use of radio-electronic devices (radios, televisions, electronic on-board systems in the car itself, etc.), their main drawback began to appear - the emission of a large amount of electromagnetic interference.

To reduce them, additional electrical resistance is used in the high-voltage circuit of the ignition system.

An interference suppression resistor can be built into the distributor rotor (slider), spark plug or spark plug cap in various combinations. In addition, the carbon electrode in the distributor cap has resistance.

Currently, an effective and most common way to reduce interference is to use high-voltage wires with distributed resistance. Design of high-voltage ignition wires Modern wires consist of a conductor, insulation (protective layer), metal contacts and caps (Fig. 1).

The conductor (Fig. 2) comes in several types:

multi-core copper with a resistance of 0.02 Ohm/m (Ohm per meter of wire length). With such wires, additional noise suppression resistors are required;
non-metallic with metal “wrap” - distributed resistance up to 2 kOhm/m. The central part of the core is made of graphite-impregnated fiberglass, flax thread or Kevlar3. It is often covered with a layer of ferroplast4, which, due to its properties, also prevents the spread of interference. A thin metal wire is wound on top. As a rule, additional noise suppression resistors are required;
non-metallic with high distributed resistance. Wires with such a core are installed without resistors.

A core of this type can be made of various materials, for example, versions are often found from:

cotton yarn impregnated with soot solution. Sometimes it is reinforced on top with cotton or nylon braiding. Resistance 15-40 kOhm/m;
polymer “core” with a resistance of 12-15 kOhm/m. A reinforcing thread may be passed inside it;
fiberglass threads with graphite sprinkling.

Insulation is a single-layer or multi-layer protective dielectric coating of the current-carrying conductor (Fig. 3). Intended for:

preventing electrical leaks;
protecting the core from moisture, fuels and lubricants, harmful vapors and high temperatures in the engine compartment, as well as mechanical damage.

Executed from various types plastics (for example, polyvinyl chloride), silicone, rubber in various combinations. Sometimes the mechanical strength of the insulation is increased by using fabric, cotton, nylon, fiberglass or polymer braiding.

Metal contacts (tips) provide electrical connection of the current-carrying core with the corresponding contacts (sockets, high-voltage terminals) of the spark plug and ignition coil or distributor cap. Primary requirements:

reliable contact with the conductive core of the wire. Achieved by crimping or soldering (with a copper core);
strength of fastening on the wire. It is achieved by tight crimping and sometimes additionally with “teeth” and a special convexity (Fig. 4);
reliable connection to the terminals of the spark plug and ignition coil or distributor cap. To do this, the wire contact may have a protrusion, a petal or a special spring;
sufficient corrosion resistance to maintain reliable contact during operation. Achieved by using non-ferrous metals or coatings that protect from external influences.

The contacts to which the high-voltage wire is connected are of several types. The most commonly used ones are shown in Fig. 5, and they may differ at different ends of the wire.

The caps protect the connections between the wire contacts and the corresponding terminals of the coil, distributor and spark plugs from aggressive environmental influences and prevent electric current leakage. Basic requirements for them:

maximum tight connection with the parts of the ignition system so that dust and moisture do not penetrate to the contacts. Sometimes, after prolonged use, it is possible to remove the caps only with the help of a special tool;
resistance to high and low temperatures, as well as to their sudden changes.

The caps have different shapes and are made of rubber, silicone, plastic or hard rubber. Some of them have an additional noise suppression resistor (Fig. 6) or a metal screen built into them to reduce interference. Malfunctions of high-voltage ignition wires Basic wire faults - break electrical circuit and current leakage.

A break in the electrical circuit most often occurs at the junction of the metal contact of the wire with the conductor and other parts of the ignition system, for example when:

removing the wire;
poor connection with the terminals of the corresponding elements of the ignition system;
oxidation or destruction of the core.

In places where the connection is broken, sparking and heating occur, which further worsens the situation and can lead to burnout of the metal contacts or core.

Electricity leakage occurs through contaminated wires, spark plugs, distributor caps and ignition coils, as well as when the insulation and wire caps are damaged, so their dielectric properties deteriorate during operation.

At low temperatures, high-voltage wires become more rigid, increasing the likelihood of damage to their insulation and caps. In addition, due to the constant vibration that accompanies engine operation, the joints become loose, which can lead to poor contact, for example in the distributor cap. Spark plug caps suffer the most from elevated temperatures, since they are closest to the heated engine parts and, moreover, often fail when removed.

Over time, all elements of the ignition system inevitably become covered with a layer of dust and dirt, moisture and vapors of fuels and lubricants, which are current conductors and significantly increase leaks, especially in wet weather and when the insulation is damaged. In addition, microcracks further increase from moisture and dirt. Recommendations for choosing high-voltage ignition wires VAZPri selection of high-voltage wires It is advisable to focus on the recommendations of both their manufacturers and engine manufacturers.

When purchasing, it is useful to carefully study the packaging. It is advisable that it indicate in Russian the models of cars or engines for which these wires are intended for installation. Failure to indicate the manufacturer of the wires and its “coordinates” is a sufficient condition for refusing to purchase. Also, you should not purchase wires whose packaging contains spelling errors, most often in the word silicon. It should be taken into account that for high-voltage automotive wires there is only the international standard ISO 3808, and there are no domestic ones, so the presence and content of inscriptions on them is determined by the manufacturer himself.

If the ignition system produces a high-voltage impulse with little energy, for example in cars with a contact ignition system (most rear-wheel drive VAZs), then you should not install wires with high distributed resistance. This will reduce the spark power and, under unfavorable conditions, the combustible mixture may misfire (for example, when starting a cold engine in winter).

Wire resistance can be measured using a tester. However, for wires with a current-carrying core wrapped around them, this method is not correct, since when working on the engine, the value of their resistance changes. This is due to their design features.

The level of interference created both by the electrical equipment of the car as a whole and by high-voltage wires can be assessed using a receiver installed in it (car radio). The order of work for such a check is given in the diagram.

When choosing wires based on insulation material, you should take into account the voltage in the ignition system of a particular car. At its maximum values, which can be indicated in the repair manual, the insulation should not allow breakdown. Wires with insulation and caps, the material of which does not become hard and brittle in the cold and can withstand high temperatures in the engine compartment, such as silicone, are preferable. In addition, it is less wetted by water, which means the likelihood of electrical breakdown is reduced. Silicone has a waxy feel to the touch, and wires made from it allow severe kinks.

When operating a vehicle, the first thing you need to do is keep the wires clean and dry. To do this, you can, for example, periodically wipe the distributor cap, ignition coils, spark plug insulators and the wires themselves with caps removed from the car with gasoline.

It is often possible to determine an insulation breakdown when the engine is running by ear (you can hear clicks) or visually. If you open the engine compartment in the dark, the location of the current leak will be visible by the spark that jumps out. In the dark, a glow (shine) is sometimes noticeable around the ignition system devices due to humidity and ionization of the air, for example before a thunderstorm, or during large current leaks.

A wire break in the wrapping of a non-metallic conductor (Fig. 2, b) may not appear at idle speed of the crankshaft and at low loads, while at high loads the engine will “triple” if the wire going to the spark plug is damaged, or stall, if the central one is faulty.

Good contact at the tips prevents loss of impulse energy transferred to the spark plugs. Therefore, it is advisable to periodically check whether the tips are properly inserted into the sockets of the corresponding elements of the ignition system.

To prevent damage to the wire, it is recommended to remove it starting from the cap, rather than pulling it out by the insulation.

The tightness of the caps at the junctions of the wires reduces oxidation of the tips and subsequent deterioration of the contact. Therefore, it is important to put the caps on completely, and if cracks appear on them, replace them.

Interference is formed due to high frequency voltage pulses in the ignition system. For domestic cars their values are as follows: rotor - up to 8 kOhm, spark plug - 4-10 kOhm, spark plug cap - 4-13 kOhm, central electrode - 8-14 kOhm. Flexible artificial material with high strength. 20% polyvinyl chloride plastic compound PDF and 80% ferrite or manganese-nickel and nickel-zinc powder. You can compare the spark energy with certain wires by connecting a spark gap instead of spark plugs on the car and cranking the engine crankshaft with the starter. In this case, it is advisable, and on cars with a catalytic converter of exhaust gases, mandatory, to turn off the fuel supply. High total resistance in the secondary circuit will make the spark appear weaker and thinner. The arrester consists of two electrodes in an insulating housing, the distance between the ends of which is 7 mm. You can simulate a spark gap by securely fastening the tip of a high-voltage wire at this distance from a metal part of the engine.

TO high voltage wires Many car enthusiasts treat them as a minor detail, and in specialized publications little attention is paid to them. And most sellers in retail outlets cannot say anything sensible; they advise what to buy based on personal sympathies and their own benefit. And that's it - wires are inserted between the ignition coil and the spark plugs, current is carried out. Wires, that's why they are wires, to conduct current. What significant difference could there be between them that affects the performance of the car? But not everything is so simple. Conduct and protect.

The main purpose of high-voltage wires is to reliably transmit high-voltage electrical impulses from the ignition coil to the spark plugs. Depending on the ignition system, the generated voltage can range from 25 kV to 50 kV. And, it would seem, the lower the electrical resistance, the less energy loss there will be, the better the ignition system will work. However, there is a downside to electrical resistance close to zero - a high level of electromagnetic interference, which has a devastating effect on the operation of a modern car stuffed with electronics. Therefore, the motto of high-quality high-voltage wires sounds almost like the American police: “Conduct and protect.” Protection functions are reduced not only to suppression of interference, but also to the prevention of other adverse phenomena.

Firstly, the wires themselves must be resistant to the aggressive environment under the hood of the car, withstand different temperatures (from -60°C to +240°C) and not lose their conductive qualities.

Secondly, the seemingly simple design of high-voltage wires should prevent current leakage up to contact with the tips of the spark plugs. Poor quality or faulty wires can damage some vehicle devices, such as the electronic system, as well as complicate the operation of the engine with other problems. Current leakage or increased resistance leads to a decrease in the strength of the impulse and, as a result, either to a slower ignition, or to “triplication” and “fading” of the engine at high speeds, or to the absence of a spark altogether, especially if the spark plugs are even slightly dirty.

As a result, dynamics decrease, fuel consumption increases (by 4-7%) and exhaust toxicity. Price or resource? High-voltage wires consist of a conductor, insulation (protective layer), metal contacts and caps. An additional element are combs that collect the wires into a bundle. If we subdivide them according to the materials used and production technology, then all high-voltage wires can be roughly classified into three categories.

The second is single-core wires with PVC or EPDM insulation (a type of polyurethane). Such products require additional noise suppression resistors; in addition, PVC insulation over time, under the influence of gasoline vapors, frost and high temperatures, becomes covered with microcracks, water penetrates into the wires, the resistance sharply decreases and current leakage occurs. It is precisely these wires that most domestically produced cars were and are equipped with. The most technologically advanced wires today are those where a conductive core made of a non-metallic material is used as a core, be it fiberglass, polymers, graphite, flax, cotton, Kevlar, as well as their combinations. And silicone insulation (in extreme cases, silicone rubber) provides high breakdown voltage and no losses in the ignition system, which increases the overall spark power, more complete fuel combustion, increased engine power and optimal gasoline consumption.

For example, silicone wires produced by the Citron concern (Stavropol Territory) can last at least 160,000 thousand kilometers without limiting their service life. At the same time, non-silicone ones - 30,000-50,000 kilometers or 2-3 years of operation in harsh Russian conditions. At the same time, more technologically advanced silicone wires cost 3-4 times more than their counterparts. So the choice of today's buyer is between price and resource.

The high-voltage wires of tomorrow are distinguished by the latest materials, which increase resistance to aggressive environments and have better insulating and environmental characteristics. For example, the American corporation Delphi Packard Electric Systems offers the global automotive industry a cable based on PPO technology, which is more durable and has 4 times higher friction resistance compared to analogues. And at the same time, it allows you to reduce the weight of the product by 25%. It is planned to equip C-class Mercedes with wires from this cable starting from 2007. It is worth noting that Delphi Packard is the world leader in the production of silicone cable products. The high-voltage wires of most American cars are made from its materials. The Citron concern was one of the first in Russia to use Delphi Packard materials in the production of wires and secured a worthy place in the market. It breaks where it breaks... In order not to miss when choosing high-voltage wires, it is worth considering several recommendations. Firstly, you should pay attention to the information indicated both on the packaging and on the wires themselves: manufacturer, applicability, etc. Very often, “leftist” manufacturers make mistakes in spelling the word “silicone” in English. The correct option is “silicone”. It's so common mistake, that even one of the most famous Russian auto publications indicated “silicon” in a large article, which means “silicon” in Russian. Secondly, pay attention to the wire caps. They must ensure a tight connection and protect the contact tips. High-quality caps are made from rubber based on silicone rubber. The wall thickness must be at least 3 mm. It is at the junction of the contact with the current-carrying conductor and other parts of the ignition system that most often the electrical network is disrupted. This usually happens either when the wires are removed (they often pull directly on the wires) or there is a poor connection to the terminals of the corresponding elements of the ignition system due to oxidation, loose fit, etc. Thirdly, you should pay attention to the quality of the high-voltage cable itself. The best ones are made of silicone, you can check their reliability in simple ways. Place the cable in an open flame - high-quality insulation should not easily melt or ignite. Twist the cable tightly. Signs of displacement, sliding between the sheath and the conductor, as well as crunching indicate poor quality of the mechanical adhesion between the sheath and the insulator. Also try to move the insulating layer longitudinally. The cable must be practically monolithic, otherwise protection may be violated during installation and removal of the wire.

High voltage zero resistance wires are the best wires for almost any car. In this article you will learn how to make wires using high-voltage cables from gas trucks and wires from a ZIL-130 car, and also using a wire PMVC.

Making high-voltage wires with your own hands is not only easy, but also cheaper than buying original ones, and the quality will be better! I will tell you how to make high-voltage wires with your own hands. The instructions are universal, such high-voltage wires are suitable for VAZ, Audi, or even Hyundai and Kia.

Why do I need high voltage resistance wires?

Every car has high-voltage wires, their task is to pass a lot of volts through themselves - up to 20,000 volts!

If we take that the volt wire is a highway, then the volt is a car. There are obstacles in the wires - resistance, and the fewer obstacles there are on the highway, the faster and more often they get to the place - the spark plugs.

Nowadays they make wires of poor quality - no copper at all, as thin as a hair, which is why such wires are scarce. Engine performance deteriorates, to the point where it stalls or it becomes impossible to start it at all. Therefore, zero resistance wires will come to the rescue, thanks to them improve engine performance, there will be traction at the bottom, and fuel consumption will decrease. It doesn’t matter whether it’s an injector or a carburetor - high-voltage wires with zero resistance are often better than the original or factory ones.

To check the resistance, simply take the simplest multimeter and attach the probe to the ends; the screen will show the real resistance of the wire. Ideally for most cars resistance more than 3 kOhm is not normal. Therefore, we begin the work of manufacturing high-voltage wires.

Do-it-yourself high-voltage zero-resistance wires made of PMVC

What are PMVC wires?– these high-voltage wires operate at low voltage (just for cars), but they are also used for neon signs and other low-current systems. Such wires are not sold in every store, but the cost will please you - about 10 rubles per meter. The resistance of the PMVC wire is zero. Making high-voltage wires from PMVC (not to be confused with PVMC!) is quite simple.

Necessary materials: old wires for your car, PMVC cable with a cross section of 0.75 mm square, and with a voltage of up to 20 kV, the wire will be designated PMVC 0.75-20.

To begin, remove the metal ferrules and caps from the old high-voltage wires. You can use WD-40 or other silicone lubricant to remove the rubber caps. Next, cut the required length from your PMVC wire and strip the insulation.

Next, crimp the tips and new wires and insert the rubber caps. High voltage wires are ready! Just in case, if you doubt the quality of your work, then carry a set of working, tested high-voltage wires.

Do-it-yourself high-voltage wires of zero resistance from GAZ, ZIL

For gas and ZIL-130 there are wires with zero resistance, the procedure is the same as with the previous version. You will need new ones HV wires from gas or ZIL-130. It is easier to find such wires in the store than a PMVK cable, so this is also a good option.

It is worth considering that the ZIL-130 may have thin wires with resistance; such wires do not need to be taken. It is worth buying wires with rubber insulation and a multilayer copper core.

Undoubtedly, the advantage of making wires from gaz-zil is that they are easier to buy, but the price for a set will be a little higher - 200-400 rubles. The resistance on them is also zero, but there is a minus. In winter, Gas and Zilov wires become tanned due to rubber insulation, so because of this, the mileage will be less than a high-voltage PMVK cable.

They write that the mileage of homemade high-voltage wires is approximately 100 thousand kilometers, although the original wires have greater resistance and a shorter mileage of no more than 60 thousand, usually 30-40 thousand km.

The classic high-voltage car wire is no different from a regular copper single-core cable, except powerful protection from high voltage radiation. The insulating layer is made of different materials. As technology develops, manufacturers are increasingly choosing a powerful and elastic material - silicone.

Until the 30s of the last century, the influence of impulse noise on automobile devices was neglected. The resistance of the copper core was close to zero. With the advent of car radios, it turned out that interference from high-voltage electrical cords creates such strong radio interference that the devices crackle and cannot be sources of pleasant sound. Engineers came up with the idea of installing a 4-15 kOhm resistor in series with the current-carrying conductor. This reduced radio interference.

Modern high-voltage wires are made with a conductive layer of graphite with a resistance of 5-20 kOhm. They can be used without an additional current limiter.

Twisted steel conductors reinforced with strong Kevlar threads with a ferrimagnetic core are also used.

The following materials are used as insulators:

polyethylene;
polyvinyl chloride;
feroplast;
silicone;
metal winding, like a screen.

Insulation is a combination of layers, distinguished by the presence of one or the other component, depending on the preferences of the manufacturer.

Symptoms and faults of high voltage cables

Among the main symptoms:

engine troits;
thrust changes unjustifiably sharply;
the engine stalls and does not start well;
fuel consumption has increased;
CO emissions increased;
BB wires spark;
engine power has decreased.

Symptoms show that the malfunction is caused by incomplete combustion of fuel and is associated with the ignition system, although similar signs of breakdowns are also typical for other car systems.

Diagnostics of high-voltage wires

If you find the above malfunctions in the operation of the car, then pay attention to the high-voltage ignition wires. In modern cars they work for quite a long time, more than 100 thousand km. But cars that have only traveled a thousand kilometers, but have been sitting in a garage without moving for more than five years, have the same problems. Microcracks appear in the insulation, and the cable penetrates the housing with high voltage.

Find a dark place, preferably in the garage, and clean the wires from any burning and grease. Start the engine and see what's going on under the hood. You will see a slight glow around the armored wires. If you don’t see it, but the engine is running, then that’s quite good. But if the glow is bright or the wires spark, then these are signs of dielectric failure.

Sometimes leaks are caused by grease or oils trapped in the tips. In this case, the voltage becomes an extremely dangerous source of car fire.

It is easy to diagnose the ignition system by the sound of the audio system. The method is only suitable for car owners with old analogue radios. As soon as problems with the cables begin, the radios crackle in sound and no power filters will help.

How to check armored wires? You can determine which one is faulty using a conventional analog or digital tester. Checking high-voltage wires does not require the qualifications of an electrician; it is enough to know how to use a multimeter and remember that no matter what product you use, the grease on the insulation must be thoroughly cleaned.

Types of conductive cores of high-voltage cables:

copper;
copper with built-in resistor;
graphite;
twisted steel winding on a dielectric.

In the first case, the resistance of the high-voltage wires will approach zero; in the next three cases it should range from 4 to 20 kOhm, depending on the brand. If the multimeter displays readings higher than this, then this is a sign that the cord is unusable. Grease on an uncleaned probe and a dirty insulation surface will distort the readings of the device. The grease can be conductive and by measuring the resistance of the wire, you can actually see the result of the resistance of the grease and not the wire.

Testing with a tester will not be able to detect dielectric failures and problems with contacts in the clamps if they are covered with grease.

How to check high-voltage wires without a multimeter? Only by bringing them with their bare end to the body of the car. The presence of a spark indicates that the circuit is working properly. The spark must be powerful and stable.

During measurements, be sure to bend the braid and insulation, especially at the connector fastening points. If the device readings change, then the device is unreliable and it is better to replace it.

How to make and replace an HF cable yourself

For example, you have determined that the armored cord of the fourth cylinder penetrates the body or is completely broken and does not affect the spark plug. Replacement required.

Replacing high-voltage wires is a simple operation that can be performed by any car enthusiast.

It is safer to purchase a complete set. Practice has shown that products from the same manufacturer produced at the same time fail almost simultaneously.

If this is an expensive solution for you, then you can make armored wires yourself. It will be much cheaper. Before you make them yourself, make sure that the connection diagram is clear to you.

To make a kit with your own hands, just purchase:

silicone vacuum hose with a diameter of 7-8 mm;
tips, you can use old ones if they are in good condition;
copper stranded cord with any suitable cross-section;
half-watt resistors with a nominal value of 1-1.5 kOhm.

The additional element necessary to smooth out radio interference in modern cars should be in the range of 10-20 kOhm. If you install one element of this rating, then there is a high probability of its failure during peak loads. It is better to distribute the load across several series-connected devices with a nominal value of 1 kOhm.

We insert a chain of do-it-yourself resistors into a silicone hose, cut it off and clean it. Then crimp the ends. To improve contact, graphite lubricant is used at the joints.

If the insulators are difficult to put on, lubricating them in a soapy solution helps.

Disadvantages of the method:

there is a high probability of contact soldering failure in high temperature conditions;
dependence of the ruler on one part;
difficulty in identifying a failed element.

If you decide to make the cables yourself, then do not forget that high-voltage wires of zero resistance are connected only through a series resistance.

High-voltage wires, order of their connection

If the distributor cover is installed correctly with your own hands, then the connection diagram for the high-voltage wires will be as follows:

distributor outlet, looking towards the front bumper, to the first cylinder;
tip looking down towards the third cylinder;
looking back to the fourth cylinder;
looking up to the second cylinder;
the central current-carrying current always goes to the ignition coil

Do not forget that the order of connecting high-voltage wires in cars is such that their length will not allow for an incorrect connection. Therefore, when making cords with your own hands, try to follow the same principle so as not to get confused.