ik04
11-24-2011, 03:06 AM
I finally got around to fixing the terrible stumbling and rough running my engine has exhibited for the last two years. I suspected the spark plug connectors were not making a solid connection with the plugs because I could hear the arcing pops in the radio when they misfired. My plan to fix the problem was easy: change plugs and toss the GRP connectors!
My suspicions were correct and very evident when I pulled the first plug and removed the rubber boot to see the plug/wire connection. Because of the design of the connectors on the ends of the wires, there is no way to get a decent fit on the end of the plugs! The design of the connectors is just plain faulty. In my case, the connectors snapped onto the end of the plugs and all were rattling loose and could be completely not in contact with the plug terminal intermittently.
I went down to Auto Zone and checked every brand of plug they had and they all fit loosely. I even put the screw-on connector on the Bosch plugs on backwards to see if that old trick worked. Nope. The connectors rely on the little tiny spring clips to make the electrical connection and the body of the connector simply slips over the end of the plug terminal. Bad design and causing my rough running and stumbling for sure!
I disassembled the coil and wires and replaced the wires into the coil with the little bump of the spring clip VISIBLY touching the small spade terminal in the coils. I then grabbed my channel locks and crushed the plug end of the connectors just enough to ensure the out-of-round shape would make contact between the connector BODY and the plug tip. The spring clip still makes a nice "snap" when it is pushed onto the plug, but the plug is now firmly connected to the connector body (barrel).
The bottom line is that after chasing my suspicions and finding a quick fix for the faulty design, my car now runs a LOT better and does not stumble or sputter like it has for the last two years...
What did I pay for these things? Over a hundred dollars? P.T. Barnum was right on this one! :eek:
My suspicions were correct and very evident when I pulled the first plug and removed the rubber boot to see the plug/wire connection. Because of the design of the connectors on the ends of the wires, there is no way to get a decent fit on the end of the plugs! The design of the connectors is just plain faulty. In my case, the connectors snapped onto the end of the plugs and all were rattling loose and could be completely not in contact with the plug terminal intermittently.
I went down to Auto Zone and checked every brand of plug they had and they all fit loosely. I even put the screw-on connector on the Bosch plugs on backwards to see if that old trick worked. Nope. The connectors rely on the little tiny spring clips to make the electrical connection and the body of the connector simply slips over the end of the plug terminal. Bad design and causing my rough running and stumbling for sure!
I disassembled the coil and wires and replaced the wires into the coil with the little bump of the spring clip VISIBLY touching the small spade terminal in the coils. I then grabbed my channel locks and crushed the plug end of the connectors just enough to ensure the out-of-round shape would make contact between the connector BODY and the plug tip. The spring clip still makes a nice "snap" when it is pushed onto the plug, but the plug is now firmly connected to the connector body (barrel).
The bottom line is that after chasing my suspicions and finding a quick fix for the faulty design, my car now runs a LOT better and does not stumble or sputter like it has for the last two years...
What did I pay for these things? Over a hundred dollars? P.T. Barnum was right on this one! :eek: