Plug lead problems

[Hil911]

I thought that I had started a thread on this but I can't find it.

I had problems with a new set of Beru plug leads: they were so tight in the Bosch cap that they didn't make contact AND they were extremely hard to pull out to fix the problem.

I had the same difficulty again today: I measured the resistance along the lead (plug cap to distributor cap) and it was infinite. The pictures below show how the pin has been lifted because so much force was required. Because everything is held so firmly centred, the copper tongue actually doesn't make contact at all when the pin is lifted as in the 2nd shot.

I'm sure that the spark jumps the small gap but it can't help. I wound a filament of copper wire around the pin when it was lifted. That gave me 4.03 kOhm which is correct but it may not last.