This is general guide only, for fitment of ignition leads. If you have any concerns or doubts, please contact your nearest Bougicord® retailer, vehicle service centre or motor mechanic for professional assistance or request them to install them for you.

To get the best results, care must be taken when fitting your new Bougicord® Inductive Core Ignition lead set.

It is important to remember that many problems can occur due to incorrect selection of lead set model application, incorrect fitment, and improper routing.

• The metal terminals inside the insulating boots must be fully engaged onto spark plug connector and ignition coil (and distributor) connection posts.
  
  
• When replacing leads, in particular burnt out leads, it is strongly advised that you check the spark plug and its ceramic insulator and connector, ignition coil and its sockets, and (if fitted) rotor and distributor cap for defects such as cracks, signs of excessive arcing, and possible corrosion.
  
  
• Leads must be kept well away from the exhaust manifolds, pipes, and super/turbocharger pipe-work, and other hot spots, sharp edges, and rub through points, etc. The original manufacturers lead routing, retainer clips, straps, protective tubing, heat shielding where fitted, etc must be reused, and if damaged they must be replaced.
  
  
• On performance-enhanced vehicles, additional heat shielding and wrapping will most likely be essential.
  
  
• Never change the firing order; otherwise, you may cause damage to the catalytic converter and engine.
  
  
• The Bougicord® boots and lead lengths may not exactly match the OEM product as we wherever possible, make design changes to enhance the products total performance and durability.

MAJOR STEPS & KEY POINTS:

1. Turn off the ignition and remove the ignition key. (For extra safety & security, you could disconnect the battery). This is to prevent anyone accidentally starting the engine while the leads fitted.
   
   
2. Let the engine cool before replacing the ignition leads, to prevent the risks of burns & injury to yourself.
   
   
3. Replace leads one by one, cylinder by cylinder, to avoid mix-up in firing order and damage to the catalytic converter and engine.
   
   
4. Follow the original lead routing and retention methods. To avoid lead dislodgement during driving, excessive rubbing of leads against sharp objects, minimise exposure to heat, & burning of the leads, etc.
   
   
5. Ensure that the spark plugs and distributor/coil connections posts are not defective or damaged before fitting the new leads. This is to avoid dielectric leakage (arcing) and damage to the boot sealing surfaces & terminals, misfire & cross firing, and importantly electrocution to anyone working near the engine.
   
   
6. Ensure that all connection points and spark plug's ceramic insulator are clean before assembling the ignition leads to the spark plug, distributor and/or coil boots & terminals. To facilitate making the connection easier, and to minimise the risk of dielectric leakage, misfiring, etc.
   
   
7. Keep the leads at the spark plug end clear of hot spots. If there is any slack in the leads keep this at the coil or distributor end, as generally this area is away from the exhaust manifold, and super/turbocharger pipe-work, etc.
   
   
8. TO THE SPARK PLUG:
   
   •  It maybe necessary, in order to gain access to the spark plugs that the engine covers, and so-on, may have to be removed. Be careful to note their position, and to retain all the parts for later re-assembly.
   
   •  Correctly, fit, spark plug boot, & terminal assembly, including those with rigid tubes, onto a spark plug, by taking care to ensure that the boot assembly is align at the angle that the spark plug is on the cylinder head.
   
   •  Push the spark plug connector end of the lead onto the spark plug until a click is auditable or is felt, as the terminal engages onto the spark plug connector.
   
   •  On some engines, particularly V8s, and front wheel drives, it is extremely difficult to obtain two hand access. Then, by using the best method you can, ensure that the ignition lead's terminal is snapped-locked onto the spark plug's connector.
   
   •  Check that the terminals are engaged correctly by gently pushing and rocking the top half of the spark plug boot (or top section of the rigid tube). There will be a loose spongy feel, if the terminal has not engaged properly. If correctly fitted, there will be a solid feel, and effort will be necessary to pull the boot and terminal off the spark plug.
   
   
9. TO THE COIL &/OR DISTRIBUTOR :
   
   •  Connect the coil (and distributor) boot and terminals assemblies into or over the coil (and distributor cap) connectors. The terminals inside the ignition lead boots must fully engage onto the connecting surfaces or connecting posts of the coil (and if applicable distributor cap) posts.
   
   •  Sometimes, due to the sealing nature of the ignition lead boots, when pushing the boot onto the posts, air can be come entrapped. To release this trapped air, simply lift the lower edge of the rubber boot up when pushing it onto the post. This will help release the trapped air.
   
   
10. FINAL CHECK :
    
    •  Best practise is to recheck the electrical connections to ensure full and positive engagement.
    
    •  Then repeat this again after the vehicle has run a few kilometres. The vibration and heat of the engine, as well as movement of the vehicle during travelling, could loosen boot and terminal connections, particularly, if they where not engaged.
    
    
11. REMOVING IGNITION LEADS TO SERVICE THE SPARK PLUGS:
    
    •  Firstly, always let the engine cool down .
    
    • Never pull on the lead to remove it from the spark plug. Always remove the lead by pulling on the boot.
    
    In some instances, corrosion may have formed between the ignitions lead terminal and spark or coil terminals, resulting in a bond. This can be usual traced to the use of poor quality lubricant. In addition, some spark plug expands inside the ignition terminal when hot, and terminals will lock onto the spark plug. All this can make removal difficult.
    
    •  On short flexible rubber boots, gently twist the boot to break the seal between boot and the spark plug's ceramic insulator. Then pull the boot up (and not the lead) and off the spark plug at the same angle as the spark plug is fitted into the engine.
    
    •  With rigid-tube, spark plug insulators avoid twisting the insulator. Pull the insulator assembly straight up, pulling it to one side could cause the terminal to be hooked into some spark plug connector. In addition, because extra force could be needed to disengage the ignition leads terminal from the spark plug's connector, the ignition cable could be separated from its terminal.
    
    •  If you consider it necessary to use a lubricant assembly aid on the ignition lead boots, we strongly recommend that you very sparingly use either a plain talcum powder, or silicone dielectric grease. Other types of lubricants breakdown under heat, form acids, and seriously en-brittle the boots and corrode the terminals and connectors.

We hope that these guidelines and precautions are of assistance and if you have any comments please contact us.

*We accept no responsibility for any errors or omissions in the above, or for any subsequent incorrect assembly, abuse, accident, or negligence, in the fitment of the ignition leads.