Hey guys, The other day i had to find a way to repair broken dizzy wiring on a 4age so i just cut the wiring down and repinned it, I did the same thing to my car today when i made the wiring harness so i thought id do a step by step guide for the FAQ.

 

Pictured is the plug with broken/exposed wiring:

 

Tools required (3mm heatshrink, Lighter or heatgun, Narva plug connector pins, Plug connector crimpers) :

 

Step 1, Cut off the wires and remove the grommet:

 

Step 2, Remove old female terminals by using a skinny pointed object to push on the holding tab while forcing the terminal out of the back of the plug:

 

(Picture of holding tab):

 

Step 3, Identify the wire locations on the distributor plug (makes it easier when putting the grommet on):

Step 4, Slide the grommet back onto the wiring harness:

 

Step 5, Put heat shrink on the wires so that approx 1cm of wiring is showing and shrink it:

 

Step 6, Pull the grommet back over the now heat shrink coated wiring:

 

Step 7, Crimp terminals onto the wiring:

 

You will end up with it looking like this:

 

Step 8, Insert the terminals into the plug and push the grommet back into the plug:

Edited August 23, 200818 yr by Trev

Final step, Once you have done that you will have a plug that has no breaks or exposed wiring that will be stronger than it previously was

 

Easily fixed with non insulated terminals, Ratchet crimpers make it a lot easier too..

 

perhaps a bit over the top with the extra heat shrink?

The ratchet crimpers are too big for the narva terminals, No the extra heatshrink gives it more flexability.

My ratchet crimps work fine with them..

Well these don't:

 

Thats because they are insulated terminal ratchet crimpers, You need a set of non insulated terminal ratchet crimpers, They are the fo-shizzle :jamie:

 

My yellow and red handled ratchet crimps (used for red, blue and yellow insulated crimps.

 

My blue handled ratchet crimps (used for non insulated QK quick connector plugs and QL type fuse link connectors)..

Ah now i see what you mean, One of the guys at work has set of them but i had to use the workshop stuff.

Well done Trev, seems to be a common problem with those Dizzy plugs, i'm sure this will be a well read topic.....

 

Thanks

Dougy

:jamie: