CHAMPION SPARK PLUGS
Dedicated to service. Driven by quality.
Categories: IGNITION | FILTERS | BRAKES | LIGHTING
PART I - HOW DOES A SPARK PLUG WORK?
A CHAMPION SPARK PLUG IN DETAIL
A detailed diagram of a spark plug shows the following parts: Terminal at the top, followed by the Insulator, the Shell, the Nut/Hex for fitting, the Gasket/Taper Seat for sealing, an internal Resistor, the Centre Electrode, the Thread for screwing into the engine, the Firing End, the Gap where the spark occurs, and the Ground Electrode at the bottom.
Champion aims to provide first-class products and comprehensive information. This brochure, Part 1, explains how a spark plug works. Part 2 covers part number structure, and Part 3 details Champion spark plug technologies.
Champion offers Original OE-quality, developed with OEMs to meet the latest ignition developments and ensure rapid information dissemination to distributors and installers.
THE SPARK PLUG IN THE ENGINE
WHAT DOES A SPARK PLUG DO?
Diesel-driven engines use glow plugs, while petrol-driven engines use spark plugs. The ignition system in petrol engines is external, initiating combustion in the compressed fuel-air mixture via an electrical spark from the spark plug.
A diagram illustrating the combustion chamber of a petrol engine shows the spark plug positioned to ignite the fuel-air mixture. It depicts the boot, spark plug, piston, valve and spring, and combustion chamber.
The spark plug generates a spark created by high voltage from the ignition coil, which leaps between electrodes. This spark ignites the fuel-air mixture, causing a rapid pressure buildup that drives the piston downwards. This motion is transferred to the crankshaft, powering the vehicle.
Each spark plug delivers sparks between 500 and 3500 times per minute.
For optimal engine performance, smooth operation, and environmental friendliness, engines require a precise fuel-air mixture and a high-energy ignition spark at the exact moment. Spark plugs must meet high performance demands, ensuring reliable ignition even in extreme conditions like -20°C, and contributing to low-emission combustion and fuel efficiency.
Champion spark plugs are designed and manufactured with high-quality materials to meet these requirements. Champion engineers collaborate with the motor industry during engine development to ensure precise adaptation to combustion chamber conditions. Champion offers a wide range of spark plugs and uses diverse materials for electrodes.
PLUG COMPONENTS IN DETAIL
EVERY CHAMPION SPARK PLUG IS COMPOSED OF FIVE MAIN COMPONENTS
- 1. Resistor: Eliminates radio frequency interference (RFI).
- 2. Shell: A threaded metal hex that seals the combustion chamber and allows installation/removal.
- 3. Heat Range: Determined by insulator and seat dimensions, it controls heat transfer from the combustion chamber to the engine head.
- 4. Electrodes (Centre and Ground): Position the spark in the ignition chamber.
- 5. Terminal and Gap: The terminal connects to the ignition system. The gap is the distance between the centre and ground electrodes, crucial for spark plug performance.
The performance and durability of a spark plug depend on its component characteristics. Champion's part numbering system provides information on these components and characteristics. Brochure Part II further explains this system.
Diagrams illustrate heat transfer within a spark plug, showing percentages of heat transferred 'in' (to the firing tip) and 'out' (via the cylinder head and to the air). Another diagram shows a spark plug with labeled components: Resistor, Shell, Heat Range, Centre electrode, Ground electrode, Projection, Gap, Terminal.
1. RESISTOR
Radio Frequency Interference (RFI) is generated by ignition systems. A built-in resistor in spark plugs eliminates RFI, ensuring perfect ignition and trouble-free operation of electronic onboard systems. Champion uses F.I.S.S. (Fired in Suppressor Seal) construction for stronger insulators and increased heat dissipation, contributing to optimum engine performance and On Board Diagnostic compatibility.
2. SHELL
Champion collaborates with car manufacturers to develop optimal solutions for each engine. The shell, a threaded metal hex, seals the combustion chamber and allows for plug installation and removal. It also conducts heat to the cylinder head and provides a ground path for the spark. Different seat types are used: Flat Seats (requiring a gasket) and Taper Seats. The table below details thread diameter, seat type, and recommended tightening torque.
| Seat Type | Thread Diameter | Tightening Torque (Nm) |
|---|---|---|
| GASKET | 10 mm | 10-15 |
| GASKET | 12 mm | 20-25 |
| GASKET | 14 mm | 25-30 |
| TAPER | 10 mm | 10-15 |
| TAPER | 12 mm | 15-20 |
| TAPER | 14 mm | 15-20 |
The nut size indication (HEX or BI-HEX) facilitates tightening. The height of the threaded part is also a key dimension.
3. HEAT RANGE
The heat range dictates how quickly a spark plug transfers heat from the combustion chamber to the engine head. This is determined by insulator dimensions and the seat. 'Cold' spark plugs have shorter insulators and dissipate heat quickly, keeping the firing tip cooler, which prevents pre-ignition in high-compression, high-performance engines. 'Hot' spark plugs have longer insulators, dissipating heat slower, keeping the firing tip hotter to burn off deposits and prevent fouling, aiding cold starts. This is particularly suited for lower output engines.
Diagrams illustrate heat transfer within a spark plug, showing percentages of heat transferred 'in' (to the firing tip) and 'out' (via the cylinder head and to the air).
4. ELECTRODES
The centre electrode, connected to the terminal, is typically made from durable materials like copper, nickel-iron, chromium, platinum, or iridium. It ejects electrons and is the hottest part. The projection is the distance from the shell's end to the ceramic nose tip. The ground electrode, usually made of nickel-steel with a copper core, is welded to the shell. Champion's Multi Ground Electrode design, featuring 2-3-4 ground electrodes, offers increased service life (up to 60,000 km / 38,000 miles) as the spark can jump to a closer electrode as wear occurs.
Champion utilizes proven technologies and premium electrode materials for enhanced service life and performance.
5. TERMINAL AND GAP
The terminal serves as the connector to the vehicle's ignition system. Champion develops specific terminal and gap configurations tailored to engine requirements. The gap, the distance between the centre and ground electrodes, is critical for spark plug performance.
CHAMPION INNOVATION: Ribbed Core Nose Feature
Champion's innovative Ribbed Core Nose feature improves anti-cold foul performance and cold start ability. It combines the ignitability of a single ground electrode with multi-ground semi-surface design benefits, eliminating channelling when the plug is fouled.
Your Champion Benefit: Improved Cold Starting and Anti Fouling
- Multi electrode semi surface performance
- F.I.S.S. technology to meet all RFI and OBD requirements
- Double copper technology for extended life (60,000+ km / 40,000+ miles)
- Excellent performance across all grades of fuel
Packaging Information
Champion spark plug packaging includes a short product code (e.g., OE220) which corresponds to Champion's technical code (e.g., KEC4PYPBF-1). A table shows examples: OE219 maps to KEC4PYPBF, OE220 maps to KEC4PYPBF-1, and OE246 maps to KEC6WYPB-1.
SAME QUALITY, DIFFERENT PLUG
Champion spark plugs are developed in close cooperation with Original Equipment (OE) manufacturers, meeting stringent requirements. Production also occurs in OE facilities, ensuring aftermarket plugs meet or exceed OE standards.
PROVEN TECHNOLOGY, PRODUCED IN WEST-EUROPE
Champion's technology is proven and produced in their global OE facilities, including the Chazelles-sur-Lyon (France) OE facility. This ensures European production and adherence to OE manufacturer standards.
LEADING VEHICLE PARC COVERAGE FOR SPARK PLUGS, AND INCREASING EVERY DAY
Champion leads the aftermarket with over 95% coverage for spark plugs, serving both automotive and non-automotive applications. OE plugs are directly available for the aftermarket, incorporating technological innovations. Regular new product introductions continuously increase coverage.
