Volkswagen Polo II (1991 - 1994) - 1992 1050cc - burnt ht lead

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Tue 4 Dec 2007 16:51
1992 1050cc - burnt ht lead - rustbucket
I have just sorted the non starting Polo that my daughter runs around in for the second time in 3years the HT lead to the centre of the Distributor cap has burnt away at the dissy cap end (leaving only the outer insulation boot of the HT cable holding it in place).As its happened again I wonder if anyone else has had this or similar.I check that the HT leads are pushed home and tight often , I did this only a few weeks ago for the MOT check and did not notice any burning ect. The fact that it has been arcing has burnt not only the HT cable but the centre pin of the dissy cap so new cable and a new cap.
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rustbucket (the original)

Edited by Webmaster on 04/12/2007 at 17:47

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Tue 4 Dec 2007 17:24
burnt ht lead - Screwloose
rb

What year and engine? Did you replace cap and leads last time? Where did they come from?

Once arcing starts, it destroys the joint very quickly.
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Tue 4 Dec 2007 17:30
burnt ht lead - rustbucket
Sorry for lack of info, K plate 1050 cc petrol. Yes last time new cap ,rotor arm and all HT leads from VW (other parts from VW lately Iam not impressed with they have brought there prices down but its seems quality has suffered).I appreciate that once arcing starts it will errode anything away and carbonise but its not as though I dont make regulare checks .
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rustbucket (the original)
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Tue 4 Dec 2007 17:44
burnt ht lead - Screwloose
rb

If it was all making a nice, tight, connexion; then it's possible that the end on the HT lead wasn't properly attached and the arcing started inside the lead.

I used to like to fit copper staples to connect the conductive core and the terminal; but the current trend is to just bend the core over and trap it under the crimp.

Still; another cap and leads should keep it going for a few more years.
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Tue 4 Dec 2007 18:20
burnt ht lead - rustbucket
Hi screwloose, yes you could be right, as the boot and lead is moulded as one you cannot see a lot so a poor crimp or the conductive core not held under the crimp could be the cause.
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rustbucket (the original)
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Tue 4 Dec 2007 20:17
burnt ht lead - rustbucket
I have now dissected the burnt moulded end the crimp is good well made and trapped all the strands of the conductor. What has failed is the carbon resistor encapsulated within the moulded part and has burnt not at the cable to restor crimp but at the resistor to sprung clip part that connects onto the dissy centre contact.Not that this solves the problem as it is still a failure of the assembly, but definately the week part.
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rustbucket (the original)
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