Connection Systems Ignition Products Catalog Delphi Packard Electric Systems Ignition Products Necessity Nudges Invention T he founders of the Packard Electric Company, James Ward and William Doud Packard, were well known for insisting on the best in materials, designs and workmanship for their product, the Packard Automobile. In 1898, this passion guided the brothers to develop their own ignition cable in order to overcome performance and availability problems with the commonly used, imported cables of that time. By 1901, the Packard Electric Company became the first U.S. producer of "high tension" automotive cable with dramatically improved performance. This product not only solved the brothers' ignition problems, but also became an industry standard. They called their insulated spark plug cable "Packard Lac-Kard Cable". What started in 1898 as a solution to a cable problem resulted in the company known today as Delphi Packard Electric Systems, the world's leading supplier of electrical and electronic distribution systems and ignition wiring products. Delphi Packard Electric Systems' rich history - spanning more than 100 years - highlights its commitment to excellence, world-class quality and outstanding value in the automotive business. Our state-of-the-art operations supply electrical and electronic distribution systems for more than 14 million vehicles each year. Today, Delphi has approximately 206,000 employees and operates 198 wholly owned manufacturing sites, 44 joint ventures, 53 customer centers and sales offices, and 31 technical centers in 43 countries. 2. Delphi Packard Electric Systems * www.delphi.com Delphi Packard Electric Systems' Ignition Milestones 1898 1901 1946 Started ignition cable development. 1948 Developed first radio suppression conductor. Developed staple terminations. Used barrel terminals. 1950 1954 1969 Used rubber spark plug boots. 1973 1975 1984 Introduced High Energy Ignition (HEI). 1985 1986 1990 Developed Composite High Temperature (CHT) core. 1991 1992 Produced wire-wound cable. 1993 Patented improved spark plug boot release agent/dielectric sealing grease. Produced first ignition cable in the U.S. Developed ignition cable with extruded-cured-synthetic rubber insulation and jacket. Introduced inner-braid cable construction. Developed strip and fold termination technique. Used EPDM insulation, fiberglass conductor and silicone spark plug boots. Developed "Delcore" aramid fiber conductor. Developed heat shields for spark plug boots and hightemperature silicone spark plug boot material. Produced Coil-At-Plug spark plug boot assembly. Developed and produced components for the Angular Based Ignition Timing System (ABITS). Produced low resistance CHT cable. Introduced new heat shield. Table of Contents Overview Delphi's Ignition Group ................................. 4 A Complete Line of Ignition Products ........ 5 Ignition Cable Typical Constructions ..................................... 6 Cable Selection Charts .................................. 7 Spark Plug Boots HEI ...................................................................... 8 Pre-HEI ............................................................ 10 HEI Deep Well ................................................ 11 Miscellaneous Deep Well Boot Components ...................................... 12 Distributor/Coil Nipples 27 KV Systems for Female Coil Towers ............................ 13 35 KV Systems for Male Coil Towers ................................ 14 Ignition Terminals Male ................................................................ 15 Female ............................................................. 16 Clips 1-Way .............................................................. 17 2-Way .............................................................. 17 3-Way .............................................................. 18 4-Way .............................................................. 19 5-Way .............................................................. 19 Heat Shields .................................................. 20 1995 Produced high tear silicone cable and low resistance inductive core. 1996 Developed new products for On Board Diagnostics systems (OBD2). 1997 1998 Produced 5mm cable. 1999 Developed terminals with welded seams and improved snap ring designs for better tactile feel and retention. 2000 2001 Introduced low capacitance cable. Miscellaneous Assemblies .................................................... 21 Position Assurance Devices ........................................................... 22 Coil-At-Plug Assemblies ............................ 22 Introduced secondary lock features for boot and nipple connections (BPA - Boot Position Assurance and NPA - Nipple Position Assurance). Part Number Index ................................................................ 23 Integrated noise suppression elements for Coil-At-Plug assemblies. Ignition Products Catalog * www.delphi.com 3. State-of-the-art manufacturing and assembly techniques result in world-class quality. The Delphi Packard Electric Systems' Ignition Group supplies high quality ignition products that meet diverse application needs for Original Equipment Manufacturers (OEM) and Delphi Aftermarket customers. Delphi's ignition cables and components exceed stringent product requirements, such as: 40,000 volt systems Temperature ranges from -40C to 260C Radio frequency interference suppression 160,000+ km product life Resistance to ozone, corona, and fluids When combined into assemblies, the ignition products function to provide: Sound mechanical connections to spark plugs, distributors, and coils Protection from weather, elements, and temperature A direct electrical path between distributors/coils and spark plugs for conventional systems and the latest technologies of Coil-Near-Plug and Coil-At-Plug 4. Delphi Packard Electric Systems * www.delphi.com A Complete Line of Ignition Products Delphi Packard Electric Systems supplies five categories of ignition products. Many combinations are available to suit different applications. Ignition Cable Ignition cable transfers high voltage energy from distributors/coils to spark plugs. It consists of: Core - conductive center that can be metallic or non-metallic Insulation - non-conductive materials that can be organic or inorganic Inner braid - serves as a strength member to enhance mechanical properties for terminal retention and overall cable durability Outer jacket - provides protection from engine fluids, temperature extremes, and abrasion Ignition Terminals Ignition terminals provide the mechanical and electrical connections between the cable core and the spark plugs, distributors, or coils. Two methods of terminal application are used: Staple - a "U" shaped metallic piece, inserted into the core, provides a contact point on the outer surface of the cable. Crimping the terminal over the staple and cable completes the connection to the core. Strip and Fold - removes insulation to expose a short length of core which is "folded" back over the outer jacket. The crimping of the terminal traps the core between the terminal and the cable. Spark Plug Boots and Distributor/Coil Nipples Spark plug boots and distributor/coil nipples provide environmental sealing and electrical insulation of the ignition lead connections to spark plugs, distributors, and coils. These parts must: Insulate the connections Resist dielectric puncture Seal against moisture and fluids present in the engine compartment Perform at engine compartment temperature extremes Be removed easily, without damage, during service Heat Shields Heat shields are metallic/ceramic outer shields that provide additional temperature protection for spark plug boots. Clips, Channels, Conduits and Other Fasteners Clips, channels, conduits and other fasteners maintain harness routings to keep assemblies away from moving parts, sources of heat, and areas of potential abrasion. Ignition Products Catalog * www.delphi.com 5. TYPE 1 - Resistive Ignition Cable - CHT Ignition Cable Jacket Inner Braid Insulation ne Delphi Packard Electric Systems produces many cable types that meet the increased energy needs of leaner burning engines, withstand high operating temperatures, and meet strict suppression requirements for electro-magnetic interference (EMI). Conductive Latex Aramid Fiber TYPE 2 - Resistive Ignition Cable - Delcore Jacket Inner Braid Insulation The core can be made with metallic or non-metallic materials. Specific core materials available are copper, stainless steel, Delcore, Composite High Temperature (CHT), and wire-wound. These choices meet a wide range of customer specifications for resistance, reactance, and capacitance. Conductive Layer Aramid Fiber TYPE 3 - Resistive Ignition Cable - Delcore (minus insulation and braid) Jacket The insulating portion of the cable can be made with organic or inorganic materials. The organic choices are Chlorinated Polyethylene Elastomer (CPE) and Ethylene Polypropylene Diene Monomer (EPDM). The inorganic option is Silicone. Delphi ignition cables are made with multiple layers of nonconductive materials over the selected core in order to optimize the desired properties of the finished cable (dielectric strength, mechanical strength, flexibility, and temperature resistance). Conductive Latex Aramid Fiber TYPE 4 - Resistive Ignition Cable - Delcore (minus braid) Jacket Insulation Conductive Layer Aramid Fiber TYPE 5 - Wire-Wound Ignition Cable Jacket Inner Braid Insulation Wound Reactive Layer Aramid Fiber TYPE 6 - Metallic (Copper or Stainless Steel) Jacket Inner Braid Insulation Copper or Stainless Steel Core 6. Delphi Packard Electric Systems * www.delphi.com Temperature/Material Range Continuous Operating Temperature Terminals 90oC to 120oC Phos. Bronze Stainless 120oC to 180oC 232oC Cable Construction Boot Material SAE J-2031 Jacket Insulation Conductor Class Ty p e EPDM or Silicone CPE EPDM EPDM Delcore, Copper or Stainless A/B/C 1 or 2 Stainless Silicone Silicone EPDM Delcore or CHT C/D/E 3 Stainless High Temp. Silicone Silicone Silicone CHT or Wirewound Core D/E/F 3 or 4 Cable Cable Size (mm) Conductor Insulation Jacket Type 8.0 CHT EPDM Silicone 1 8.0 CHT Silicone Silicone 1 7.0 CHT CPE EPDM 1 7.0 CHT EPDM EPDM 1 7.0 CHT EPDM Silicone 1 7.0 CHT Silicone Silicone 1 8.0 Delcore EPDM EPDM 2 7.0 Delcore EPDM CPE 2 7.0 Delcore EPDM EPDM 2 7.0 Delcore EPDM Silicone 2 8.0 Delcore - EPDM 3 7.0 Delcore - EPDM 3 8.0 Delcore EPDM Silicone 4 7.0 Delcore EPDM EPDM 4 8.0 Inductive Wire-Wound EPDM Silicone 5 8.0 Inductive Wire-Wound Silicone Silicone 5 7.0 Inductive Wire-Wound EPDM CPE 5 7.0 Inductive Wire-Wound EPDM Silicone 5 7.0 Inductive Wire-Wound Silicone Silicone 5 5.0 Inductive Wire-Wound EPDM Silicone 5 5.0 Inductive Wire-Wound Silicone Silicone 5 8.0 Tin Silicone Silicone 6 7.0 Stainless Steel Silicone Silicone 6 7.0 Tin EPDM CPE 6 7.0 Tin EPDM EPDM 6 7.0 Tin EPDM Silicone 6 7.0 Tin Silicone Silicone 6 Standard Packs: 8.0mm = 8,000 ft. 7.0mm = 10,000 ft. 5.0mm = 20,000 ft. Ja cke t Colors Black Gray Rust Red Blue Yellow * Custom colors may be available upon request. * CPE is available only in black. * Jacket printed to customer specifications in white, yellow or black. Ignition Products Catalog * www.delphi.com 7. Spark Plug Boots -- HEI TYPE 1 TYPE 2 TYPE 3 TYPE 4 TYPE 5 TYPE 6 TYPE 7 TYPE 8 Note: Reference dimensions are in millimeters. 8. Delphi Packard Electric Systems * www.delphi.com Spark Plug Boots -- HEI TYPE 9 TYPE 10 TYPE 11 TYPE 12 Spark Plug Boots - HEI Part Number Type Cable Size (mm) Material Color Mating End ID (mm) Dim. A (mm) Cont. Op. Temp.(C) Peak Op. Temp.(C) 1203 3831 1204 0782 1206 5779 1216 3666 1 1 1 1 8.0 7.0 7.0 7.0 Silicone Silicone Silicone High Temp. Sil. Black Black Brown Brown 8.64 8.64 8.64 9.25 36.90 36.90 36.90 36.90 180 180 220 220 210 210 250 250 1203 4559 1213 2297 1203 3829 1202 0929 2 2 3 4 7.0 7.0 8.0 7.0 Silicone High Temp. Sil. Silicone Silicone Black Black Black Black 9.10 9.10 9.14 9.30 44.20 44.20 66.50 79.20 180 220 180 180 210 250 210 210 1204 7595 1211 0939 4 5 7.0 7.0 High Temp. Sil. Silicone Brown Black 9.30 9.10 79.30 74.80 220 180 250 210 1204 0990 1206 5732 6 6 8.0 8.0 High Temp. Sil. High Temp. Sil. Brown Brown 9.10 9.10 68.70 92.00 220 220 250 250 1205 2869 1213 2264 6 6 7.0 7.0 High Temp. Sil. Silicone Brown Black 9.25 9.25 68.70 97.00 220 180 250 210 1204 7598 1206 5735 7 7 8.0 8.0 High Temp. Sil. High Temp. Sil. Brown Brown 9.30 9.10 111.70 94.75 220 220 250 250 1209 2940 1211 0915 8 9 7.0 7.0 Silicone High Temp. Sil. Black Brown 9.25 9.10 108.00 62.00 180 220 210 250 1533 6910 1533 6923 1533 6950 10 11 12 7.0 7.0 7.0 Silicone High Temp. Sil. High Temp. Sil. Black Black Black 9.25 9.25 9.25 32.30 67.00 67.00 180 220 220 210 250 250 Ignition Products Catalog * www.delphi.com 9. Spark Plug Boots -- Pre-HEI TYPE 2 TYPE 1 TYPE 3 Spark Plug Boots - Pre-HEI Part Number Type Cable Size (mm) Material Color Mating End ID (mm) Dim. A (mm) Cont. Op. Temp.(C) Peak Op. Temp.(C) 0890 5588 1 7.0 Silicone Gray 9.78 66.60 180 210 0298 4274 2 7.0 Silicone Red 9.40 36.91 180 210 1213 2221 3 7.0 Silicone Orange 9.65 88.90 180 210 Note: Reference dimensions are in millimeters. 10. Delphi Packard Electric Systems * www.delphi.com Spark Plug Boots -- HEI Deep Well TYPE 1 TYPE 2 TYPE 3 TYPE 4 TYPE 5 TYPE 6 Spark Plug Boots - HEI Deep Well Part Number Type Cable Size (mm) Material Color Mating End ID (mm) Dim. A (mm) Dim. B (mm) Dim. C (mm) Cont. Op. Temp.(C) Peak Op. Temp.(C) 1206 5756 1209 2997 1213 2231 1213 2262 1533 6911 1216 3661 1209 2945 1213 2268 1216 3642 1 2 3 3 4 5 6 6 6 8.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 Silicone Silicone Silicone Silicone Silicone Silicone Silicone Silicone Silicone Black Black Black Black Black Black Red Black Black 9.60 9.25 9.25 9.25 9.25 9.25 9.00 9.00 9.00 126.00 127.50 124.50 124.50 172.65 134.00 104.00 104.00 100.00 24.5 74.5 31.0 27.0 - 34.0 26.9 26.9 29.0 100.85 99.00 94.50 94.50 149.70 99.50 56.50 56.50 65.50 180 180 180 180 180 180 180 180 180 210 210 210 210 210 210 210 210 210 Ignition Products Catalog * www.delphi.com 11. Miscellaneous Deep Well Boot Components 1213 2213 1213 2270 1213 2271 Extenders Part Number Description Cable Size (mm) Material Color Dim. A (mm) Mating Parts 1213 2213 Extender 7.0 PBT Black 182.3 1213 2214, 1213 2215, 1213 2216 1213 2270 Extender 7.0 PET Black 163.2 1213 2251, 1216 3620 1213 2271 Extender 7.0 UPE Black 136.9 1213 2251, 1213 2275 1213 2214 1213 2275 1216 3620 1213 2215 Seals Part Number Material Color Inside Dia. (mm) 1213 2214 Silicone Black 9.25 21.0 25.0 Plug 1213 2215 1213 2275 1216 3620 Silicone Hi-Tear Silicone Silicone Black Gray Light Gray - 9.25 9.25 34.5/36.0 21.0 21.0 13.5 25.0 25.0 Well Plug Plug 1213 2216 Outside Dia. (mm) Length (mm) 1213 2251 Application 1213 2279 Tops and Caps 12. Part Number Cable Size (mm) Material Color Dim. A (mm) Note 1213 2216 7.0 Silicone Black 36.0 Dress wire at 97.5 1213 2251 7.0 Hi-Tear Silicone Black 25.0 Seals a 28.0 mm ID well Part is vented 1213 2279 7.0 Silicone Black 25.0 Seals a 28.0 mm ID well Part is vented Delphi Packard Electric Systems * www.delphi.com Distributor/Coil Nipples - 27 KV Systems for Female Coil Towers TYPE 1 TYPE 2 TYPE 3 TYPE 4 TYPE 5 TYPE 6 TYPE 7 Distributor/Coil Nipples - 27 KV Systems Part Number Type Cable Size (mm) Material Color Mating End ID (mm) Dim. A (mm) Cont. Op. Temp.(C) Peak Op. Temp.(C) 0297 3999 1208 4632 0891 1753 0298 9836 0298 9837 1200 4921 1204 1278 1213 2250 1209 2946 1213 2248 1 1 2 3 3 4 5 5 6 7 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 EPDM EPDM EPDM EPDM EPDM EPDM Silicone Hi-Tear Sil. Silicone EPDM Black Black Black Black Black Black Black Black Black Black 15.09 19.10 15.09 14.99 17.15 15.40 14.20 14.70 17.00 17.05 18.75 20.65 18.75 33.40 37.10 33.40 26.00 26.01 43.00 37.10 80 90 80 90 90 80 180 180 180 180 110 120 110 120 120 110 210 210 210 210 Ignition Products Catalog * www.delphi.com 13. Distributor/Coil Nipples - 35 KV Systems for Male Coil Towers TYPE 1 TYPE 2 TYPE 3 TYPE 4 TYPE 5 TYPE 6 TYPE 7 TYPE 8 Distributor/Coil Nipples - 35 KV Systems 14. Part Number Type Cable Size (mm) Material Color Mating End ID (mm) Dim. A (mm) Dim. B (mm) Cont. Op. Temp.(C) Peak Op. Temp.(C) 1201 5572 1203 4134 1 1 8.0 8.0 EPDM Silicone Black Black 8.64 8.64 36.96 36.96 26.04 26.00 90 180 120 210 1205 9511 1206 5765 1208 4633 1201 5571 1 1 1 2 8.0 7.0 7.0 8.0 Silicone Silicone Silicone EPDM Black Black Black Black 8.20 8.20 9.00 8.89 36.90 37.20 37.20 38.10 21.20 21.35 26.00 22.10 180 180 180 90 210 210 210 120 1206 5743 1213 2253 3 4 7.0 7.0 Silicone Silicone Black Black 7.80 12.35 67.40 61.50 - - 180 90 210 120 1213 2218 1213 2200 1213 2219 5 6 7 7.0 7.0 7.0 Silicone Silicone Silicone Black Black Black 17.50 17.50 12.35 59.00 41.40 36.50 - - 49.80 180 180 90 210 210 120 1213 2286 1213 2280 7 8 7.0 7.0 Silicone Silicone Black Black 14.90 12.35 36.50 36.50 49.80 37.50 90 180 120 210 1216 3658 8 7.0 Silicone Black 14.90 38.50 37.50 90 120 Delphi Packard Electric Systems * www.delphi.com Ignition Terminals - Male TYPE 1 TYPE 3 TYPE 2 TYPE 4 Ignition Terminals - Male Part Number Type Cable Size (mm) Material Application Dim. A (mm) Suggested Termination Suggested Cable 1201 0248 1201 5217 1213 2249 1 2 2 7.0 7.0 7.0 Brass Brass Stainless Steel Distributor or Coil Distributor or Coil Distributor or Coil 26.57 17.15 21.00 Strip & Fold Strip & Fold Strip & Fold Silicone CPE Hi-Tear Silicone 1209 2943 1213 2247 3 4 7.0 7.0 Stainless Steel Stainless Steel Distributor or Coil Distributor or Coil 25.70 22.15 Strip & Fold Strip & Fold Silicone Silicone Ignition Products Catalog * www.delphi.com 15. Ignition Terminals - Female TYPE 1 TYPE 2 TYPE 3 TYPE 4 TYPE 5 TYPE 6 TYPE 7 Ignition Terminals - Female 16. Part Number Type Cable Size (mm) Material Application Dim. A (mm) Suggested Termination Suggested Cable 1213 2295 1 7.0 - 8.0 Stainless Steel Spark Plug 13.10 Strip & Fold Silicone 1533 6971 1209 2974 1216 3664 1209 2942 1216 3623 1216 3649 1216 3697 1 2 2 3 4 4 4 7.0 - 8.0 7.0 - 8.0 7.0 - 8.0 7.0 7.0 - 8.0 7.0 - 8.0 7.0 - 8.0 Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Spark Plug Spark Plug Spark Plug Spark Plug Coil/Plug Spark Plug Coil/Plug 13.10 62.87 62.87 51.02 23.88 23.88 23.50 Strip & Fold Strip & Fold Strip & Fold Strip & Fold Strip & Fold Strip & Fold Strip & Fold Silicone Silicone Silicone Silicone Silicone Silicone Silicone 1213 2237 1216 3665 1533 6905 1209 2977 1213 2201 5 5 5 6 7 7.0 - 8.0 7.0 - 8.0 7.0 - 8.0 7.0 7.0 Stainless Steel Stainless Steel Stainless Steel Stainless Steel Phosphor Bronze Dist./Spark Plug Dist./Spark Plug Dist./Spark Plug Dist./Coil Dist./Coil 34.25 34.25 34.25 24.75 23.40 Strip & Fold Strip & Fold Strip & Fold Strip & Fold Strip & Fold Silicone Silicone Silicone Silicone Silicone Delphi Packard Electric Systems * www.delphi.com Clips: 1- and 2-Way 1205 2039 1206 5740 1213 2228 cover Clips 1-Way Part Number Cable Size (mm) Material Color Cover 1205 2039 1206 5740 1213 2228 8.0 7.0 7.0 PA6 PA6 PA66 Black Black Black 1208 4629 1208 4629 Attached 1 2 3 0297 7417 0891 7143 1203 3809 1203 4424 1206 5759 1213 2229 A cover B Clips 2-Way Part Number Cable Size (mm) Material Color Cover Photo Location 0297 7417 0891 7143 1203 3809 1203 4424 1206 5759 1213 2229 7.0 8.0 8.0 7.0 7.0 7.0 PA66 PA66 PA66 PA66 High IM PA6 PA66 Black Med. Gray Black Black Black Black - - - Attached 1204 5668 Attached A-1 A-2 A-3 B-1 B-2 B-3 Ignition Products Catalog * www.delphi.com 17. Clips: 3-Way 1 2 3 4 3 - Way 0890 5417 0891 7255 0135 2299 0891 7538 1204 7524 1203 4564 1208 4623 1205 2871 1205 9530 1209 2941 A 1205 2037 1205 2041 cover cover B 1206 5757 1216 3607 1216 3608 1213 2208 C Clips 3-Way Cable Part Size Number (mm) 0135 2299 7.0 0890 5417 7.0 0891 7255 8.0 0891 7538 8.0 1203 4564 7.0 1204 7524 7.0 1205 2037 8.0 1205 2041 8.0 1205 2871 7.0 1205 9530 8.0 1206 5757 8.0 1208 4623 8.0 1209 2941 7.0 1213 2208 7.0 1216 3607 7.0 1216 3608 8.0 18. Material Color Cover PP PP PP PA66 HS IM PA6 PA66 HS IM PA6 PA6 PA66 HS IM PA66 High IM PA66 HS IM PA66 HS IM PA66 HIGH IM PA66 IM PA66 IM PA66 IM Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black - Attached Attached - Attached - 12084650 12084650 - Attached - Attached Attached Attached Attached Attached Photo Location A-1 A-2 A-2 A-3 A-4 A-3 B-1 B-2 B-3 B-4 C-1 A-4 B-4 C-2 C-3 C-3 Delphi Packard Electric Systems * www.delphi.com Clips: 4- and 5-Way 1 2 3 4 4 - Way 0296 5736 0629 4103 0891 7256 0891 1429 1202 0208 1200 4899 1203 4561 cover cover A 1202 0209 1202 0840 1202 0704 1204 1376 cover B 1202 0947 1203 4425 1205 9510 1213 2223 1213 2267 1213 2272 cover 1206 5758 1206 5767 C D Clips 4-Way Part Number Cable Size (mm) Material Color Cover Photo Location 0296 5736 0629 4103 0891 1429 0891 7256 1200 4899 1202 0208 1202 0209 1202 0704 1202 0840 1202 0947 1203 4425 1203 4561 1204 1376 1205 9510 1206 5758 1206 5767 1213 2223 1213 2267 1213 2272 7.0 7.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 7.0 7.0 7.0 7.0 7.0 8.0 7.0 7.0 7.0 7.0 PA66 PP PA66 HSIM PP PA66 HSIM PA66 HSIM PA66 IM PA66 High IM PA6 PA6 PA66 High IM PA66 HSIM PA6 PEI PA66 HSIM PA66 HSIM PA66 HSIM PP PA66 Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Black Gray Black Attached 1206 5761 Attached 1206 5761 1206 5761 0891 7439 Attached Attached Attached Attached 1206 5761 Attached 1205 9514 Attached Attached Attached A-1 A-2 A-3 A-2 A-4 A-3 B-1 B-3 B-4 C-1 C-2 A-4 B-3 C-3 C-4 C-4 D-1 D-2 D-3 Ignition Products Catalog * www.delphi.com 5 - Way 1204 1472 Clips 5-Way Part Number Cable Size (mm) Material Color Cover 1204 1472 8.0 PA6 Med. Gray Attached 19. Heat Shields 1213 2259 1216 3646 1533 6959 Heat Shields Part Number Description Material Plug Type Boot Cont. Op. Temp.(C) 1213 2259 Heat Shield/ Barrier Asm. Aluminum, Polyimide Film Stainless Steel Spring Small/Large 1213 2264 260 1216 3646 Heat Shield Aluminum Small 1206 5779 260 1533 6959 Heat Shield/ Barrier Asm. Aluminum, Polyimide Film Stainless Steel Spring Small/Large 1205 2869 260 Note: Reference dimensions are in millimeters. 20. Delphi Packard Electric Systems * www.delphi.com Miscellaneous Assemblies 1213 2224 Integrated Direct Ignition Assembly Asm. Number 1213 2224 1213 2220 1213 2287 Components Material Color Boot Silicone Black Retainer PA66 HS IM Black Spring Terminal 302 SS - 1213 2254 1213 2282 1216 3659 Nipple Assemblies Asm. Number Insert Nipple 1213 2220 1213 2241 1213 2219 1213 2254 1213 2241 1213 2253 1213 2282 1213 2241 1213 2280 1213 2287 1213 2241 1213 2286 1216 3659 1213 2241 1216 3658 1213 2241 Insert Ignition Products Catalog * www.delphi.com 21. Position Assurance Devices 1216 3694 2100 8514 NPA - Nipple Position Assurance BPA - Boot Position Assurance Coil-At-Plug Assemblies 1216 5490 1216 3650 Coil-At-Plug Assemblies Asm. Number Boot Number Spring Number 1216 3650 1216 3669 1216 3671 1216 5490 1216 3647 1216 3606 Note: Reference dimensions are in millimeters. 22. Delphi Packard Electric Systems * www.delphi.com Part Number Index Part No. Description 0135 2299 Clip - 3-Way 0296 5736 Clip - 4-Way 0297 3999 Page Part No. Description 18 1205 2869 Spark Plug Boot - HEI 19 1205 2871 Clip - 3-Way Dist./Coil Nipple - 27 KV 13 1205 9510 Clip - 4-Way 0297 7417 Clip - 2-Way 17 1205 9511 0298 4274 Spark Plug Boot - Pre-HEI 10 0298 9836 Dist./Coil Nipple - 27 KV 13 0298 9837 Dist./Coil Nipple - 27 KV 0629 4103 Page Part No. Description Page 9 1213 2247 Male Terminal 15 18 1213 2248 Dist./Coil Nipple - 27 KV 13 19 1213 2249 Male Terminal 15 Dist./Coil Nipple - 35 KV 14 1213 2250 Dist./Coil Nipple - 27 KV 13 1205 9530 Clip - 3-Way 18 1213 2251 Top/Cap 12 1206 5732 Spark Plug Boot - HEI 9 1213 2253 Dist./Coil Nipple - 35 KV 14 13 1206 5735 Spark Plug Boot - HEI 9 1213 2254 Nipple Assembly 21 Clip - 4-Way 19 1206 5740 Clip - 1-Way 17 1213 2259 Heat Shield 20 0890 5417 Clip - 3-Way 18 1206 5743 Dist./Coil Nipple - 35 KV 14 1213 2262 Spark Plug Boot - HEI Deep Well 11 0890 5588 Spark Plug Boot - Pre-HEI 10 1206 5756 Spark Plug Boot - HEI Deep Well 11 1213 2264 Spark Plug Boot - HEI 0891 1429 Clip - 4-Way 19 1206 5757 Clip - 3-Way 18 1213 2267 Clip - 4-Way 19 0891 1753 Dist./Coil Nipple - 27 KV 13 1206 5758 Clip - 4-Way 19 1213 2268 Spark Plug Boot - HEI Deep Well 11 0891 7143 Clip - 2-Way 17 1206 5759 Clip - 2-Way 17 1213 2270 Extender 12 0891 7255 Clip - 3-Way 18 1206 5765 Dist./Coil Nipple - 35 KV 14 1213 2271 Extender 12 0891 7256 Clip - 4-Way 19 1206 5767 Clip - 4-Way 19 1213 2272 Clip - 4-Way 19 0891 7538 Clip - 3-Way 18 1206 5779 Spark Plug Boot - HEI 9 1213 2275 Seal 12 1200 4899 Clip - 4-Way 19 1208 4623 Clip - 3-Way 18 1213 2279 Top/Cap 12 1200 4921 Dist./Coil Nipple - 27 KV 13 1208 4632 Dist./Coil Nipple - 27 KV 13 1213 2280 Dist./Coil Nipple - 35 KV 14 1201 0248 Male Terminal 15 1208 4633 Dist./Coil Nipple - 35 KV 14 1213 2282 Nipple Assembly 21 1201 5217 Male Terminal 15 1209 2940 Spark Plug Boot - HEI 9 1213 2286 Dist./Coil Nipple - 35 KV 14 1201 5571 Dist./Coil Nipple - 35 KV 14 1209 2941 Clip - 3-Way 18 1213 2287 Nipple Assembly 21 1201 5572 Dist./Coil Nipple - 35 KV 14 1209 2942 Female Terminal 16 1213 2295 Female Terminal 16 1202 0208 Clip - 4-Way 19 1209 2943 Male Terminal 15 1213 2297 Spark Plug Boot - HEI 1202 0209 Clip - 4-Way 19 1209 2945 Spark Plug Boot - HEI Deep Well 11 1216 3607 Clip - 3-Way 1202 0704 Clip - 4-Way 19 1209 2946 Dist./Coil Nipple - 27 KV System 13 1216 3608 Clip - 3-Way 18 1202 0840 Clip - 4-Way 19 1209 2974 Female Terminal 16 1216 3620 Seal 12 1202 0929 Spark Plug Boot - HEI 9 1209 2977 Female Terminal 16 1216 3623 Female Terminal 16 1202 0947 Clip - 4-Way 19 1209 2997 Spark Plug Boot - HEI Deep Well 11 1216 3642 Spark Plug Boot - HEI Deep Well 11 1203 3809 Clip - 2-Way 17 1211 0915 Spark Plug Boot - HEI 9 1216 3646 Heat Shield 20 1203 3829 Spark Plug Boot - HEI 9 1211 0939 Spark Plug Boot - HEI 9 1216 3649 Female Terminal 16 1203 3831 Spark Plug Boot - HEI 9 1213 2200 Dist./Coil Nipple - 35 KV 14 1216 3650 Coil-At-Plug Assembly 22 1203 4134 Dist./Coil Nipple - 35 KV 14 1213 2201 Female Terminal 16 1216 3658 Dist./Coil Nipple - 35 KV 14 1203 4424 Clip - 2-Way 17 1213 2208 Clip - 3-Way 18 1216 3659 Nipple Assembly 21 1203 4425 Clip - 4-Way 19 1213 2213 Extender 12 1216 3661 Spark Plug Boot - HEI Deep Well 11 1203 4559 Spark Plug Boot - HEI 9 1213 2214 Seal 12 1216 3664 Female Terminal 16 1203 4561 Clip - 4-Way 19 1213 2215 Seal 12 1216 3665 Female Terminal 16 1203 4564 Clip - 3-Way 18 1213 2216 Top/Cap 12 1216 3666 Spark Plug Boot - HEI 1204 0782 Spark Plug Boot - HEI 9 1213 2218 Dist./Coil Nipple - 35 KV 14 1216 3694 Nipple Position Assurance 22 1204 0990 Spark Plug Boot - HEI 9 1213 2219 Dist./Coil Nipple - 35 KV 14 1216 3697 Female Terminal 16 1204 1278 Dist./Coil Nipple - 27 KV 13 1213 2220 Nipple Assembly 21 1216 5490 Coil-At-Plug Assembly 22 1204 1376 Clip - 4-Way 19 1213 2221 Spark Plug Boot - Pre-HEI 10 1533 6905 Female Terminal 16 1204 1472 Clip - 5-Way 19 1213 2223 Clip - 4-Way 19 1533 6910 Spark Plug Boot - HEI 1204 7524 Clip - 3-Way 18 1213 2224 Integrated Direct Ignition Asm. 21 1533 6911 Spark Plug Boot - HEI Deep Well 1204 7595 Spark Plug Boot - HEI 9 1213 2228 Clip - 1-Way 17 1533 6923 Spark Plug Boot - HEI 1204 7598 Spark Plug Boot - HEI 1205 2037 Clip - 3-Way 1205 2039 1205 2041 9 9 18 9 9 11 9 9 1213 2229 Clip - 2-Way 17 1533 6950 Spark Plug Boot - HEI 18 1213 2231 Spark Plug Boot - HEI Deep Well 11 1533 6959 Heat Shield Clip - 1-Way 17 1213 2237 Female Terminal 16 1533 6971 Female Terminal 16 Clip - 3-Way 18 1213 2241 Insert 21 2100 8514 Boot Position Assurance 22 Ignition Products Catalog * www.delphi.com 9 20 23. Packard Electric Systems 408 Dana Street P.O. Box 431 Warren, Ohio 44486 U.S.A. Tel: [1] 330.759.6000 Fax: [1] 330.759.6085 www.delphi.com This 2001 Ignition Products catalog contains information and application guidelines for Delphi Packard Electric Systems' ignition products. These products are subjected to extensive mechanical, electrical and environmental testing procedures to help assure superior quality and performance. We have made every effort to ensure that the information contained in this document is accurate, however, changes are often made to update our specifications or part numbers. A sales engineer can help you determine which product best suits your application guidelines. Our global engineering, manufacturing network and distribution capabilities are available to help select the most suitable products. Use this catalog as a guide only. For additional information and specifications, please contact your sales account manager. Specifications are subject to change without notice. Printed on Recycled Paper. (c) 2001, Delphi. All rights reserved. Printed in U.S.A. DP-01-E-048 601/1M-WP