Ignition & Injection Systems

OBJECTIVES
After studying Chapter 21, the reader will be able to:

1. Prepare for ASE Engine Performance (A8) certification test
content area B (Ignition System Diagnosis and Repair).
2. Describe the procedure used to check for spark.
3. Discuss what to inspect and look for during a visual
inspection of the ignition system.
4. List the steps necessary to check and/or adjust ignition
timing on engines equipped with a distributor.
5. Describe how to test the ignition system using an
oscilloscope.
Automotive Fuel and Emissions Control Systems, 2/e

By James D. Halderman and Jim Linder
2009 Pearson Higher Education, Inc.

Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHECKING FOR SPARK

Typical causes of a no-spark (intermittent spark)
condition include the following:
Weak ignition coil

Low or no voltage to the primary (positive) side of the coil
High resistance or open coil wire, or spark plug wire
Negative side of the coil not being pulsed by the ignition
module
Defective pickup coil
Defective module


CHECKING FOR SPARK
FIGURE 21-1 A spark tester looks like a regular spark plug with an alligator clip attached
to the shell. This tester has a specified gap that requires at least 25,000 volts (25 kV) to
fire.

CHECKING FOR SPARK
FIGURE 21-2 A close-up showing the recessed center electrode on a spark tester. It is
recessed 3/8 in. into the shell and the spark must then jump another 3/8 in. to the shell
for a total gap of 3/4 in.

ELECTRONIC IGNITION TROUBLESHOOTING

PROCEDURE
When troubleshooting any electronic ignition system
for no spark, follow these steps to help pinpoint the
exact cause of the problem:
Turn the ignition on (engine off) and, using either a
voltmeter or a test light, test for battery voltage available
at the positive terminal of the ignition coil.
Connect the voltmeter or test light to the negative side of
the coil and crank the engine.


IGNITION COIL TESTING USING AN OHMMETER

To test the primary coil winding resistance, take the
following steps:
Set the meter to read low ohms.
Measure the resistance between the positive terminal and
the negative terminal of the ignition coil.
To test the secondary coil winding resistance, follow

these steps:
Set the meter to read kilohms (k).
Measure the resistance between either primary terminal
and the secondary coil tower.


IGNITION COIL TESTING USING AN OHMMETER
FIGURE 21-3 Checking an ignition coil

using a multimeter set to read ohms.
(Courtesy of Fluke Corporation)


PICKUP COIL TESTING

The pickup coil can be
tested for proper voltage
output.
During cranking, most
pickup coils should produce
a minimum of 0.25 volt AC.
This can be tested with the
distributor out of the vehicle
by rotating the distributor
drive gear by hand.

FIGURE 21-4 Measuring the resistance of an

HEI pickup coil using a digital multimeter set to
the ohms position. The reading on the face of
the meter is 0.796 k or 796 ohms in the middle
of the 500- to 1,500-ohm specifications.
TESTING MAGNETIC SENSORS

If the sensor is removed from the engine, hold a
metal (steel) object against the end of the sensor.
It should exert a strong magnetic pull on the steel
object. If not, replace the sensor.
Then, the sensor can be tested using a digital meter
set to read AC volts.


TESTING MAGNETIC SENSORS
FIGURE 21-5 An AC voltage is

produced by a magnetic sensor. Most
sensors should produce at least 0.1
volt AC while the engine is cranking if
the pickup wheel has many teeth. If
the pickup wheel has only a few teeth,
you may need to switch the meter to
read DC volts and watch the display
for a jump in voltage as the teeth pass
the magnetic sensor. (Courtesy of
Fluke Corporation)


TESTING HALL-EFFECT SENSORS

As with any other sensor, the output of the Halleffect sensor should be tested first.
Using a digital voltmeter, check for the presence of
a changing DC (digital hi-low) voltage when the
engine is being cranked.
The best test is to use an oscilloscope and observe
the waveform.


TESTING HALL-EFFECT SENSORS
FIGURE 21-6 (a) The connection

required to test a Hall-effect sensor.
(b) A typical waveform from a Halleffect sensor.


TESTING OPTICAL SENSORS
FIGURE 21-7 (a) The low-resolution signal has the same number of pulses as the engine
has cylinders. (b) A dual-trace pattern showing both the low-resolution signal and the highresolution signals that usually represent 1 degree of rotation. (Courtesy of Fluke
Corporation)

BAD WIRE? REPLACE THE COIL!
FIGURE 21-8 A track inside an ignition coil is not a short, but rather a low-resistance path or
hole that has been burned through from the secondary wiring to the steel core.

TESTING FOR POOR PERFORMANCE

A simple method of testing
a distributorless (wastespark systems) ignition with
the engine off involves
removing the spark plug
wires (or connectors) from
the spark plugs (or coils or
distributor cap) and
installing short lengths (2
in.) of rubber vacuum hose
in series.

FIGURE 21-9 A length of vacuum hose being

used for a coil wire. The vacuum hose is
conductive because of the carbon content of
the rubber in the hose. This hose measures
only 1,000 ohms and was 1 ft long, which is
lower resistance than most spark plug wires.
Notice the spark from the hoses surface to the
tip of a grounded screwdriver.
TESTING FOR POOR PERFORMANCE
FIGURE 21-10 Using a

vacuum hose and a
grounded test light to
ground one cylinder at a
time on a DIS. This works
on all types of ignition
systems and provides a
method for grounding out
one cylinder at a time
without fear of damaging
any component.


TESTING FOR A NO-START CONDITION

A no-start condition (with normal engine cranking
speed) can be the result of either no spark or no
fuel delivery.
Computerized engine control systems use the
ignition primary pulses as a signal to inject fuela
port or throttle-body injection (TBI) style of fuelinjection system. If there is no pulse, then there is
no squirt of fuel.


FIRING ORDER
Firing order means the
order that the spark is
distributed to the correct
spark plug at the right time.
The firing order of an
engine is determined by
crankshaft and camshaft
design.
The firing order is
determined by the location
of the spark plug wires in
the distributor cap of an
engine equipped with a
distributor.
FIGURE 21-11 The firing order is

cast or stamped on the intake
manifold on most engines that have
a distributor ignition.

SECONDARY IGNITION INSPECTION

Inspect a distributor cap for a worn or cracked
center carbon insert, excessive side insert wear or
corrosion, cracks, or carbon tracks, and check the
towers for burning or corrosion by removing spark
plug wires from the distributor cap one at a time.


FIGURE 21-12 Note where the high-voltage spark jumped through the plastic
rotor to arc into the distributor shaft. Always check for a defective spark plug(s)
when a defective distributor cap or rotor is discovered. If a spark cannot jump to
a spark plug, it tries to find a ground path wherever it can.

FIGURE 21-13 Carbon track in

a distributor cap. These faults
are sometimes difficult to spot
and can cause intermittent
engine missing. The usual
cause of a tracked distributor
cap (or coil, if it is a
distributorless ignition) is a
defective (open) spark plug
wire.


FIGURE 21-14
Corroded terminals on
a waste-spark coil can
cause misfire
diagnostic trouble
codes to be set.


SPARK PLUG WIRE INSPECTION

Spark plug wires should be visually inspected for
cuts or defective insulation and checked for
resistance with an ohmmeter.
Good spark plug wires should measure less than
10,000 ohms per foot of length.
Faulty spark plug wire insulation can cause hard starting
or no starting in damp weather conditions.


FIGURE 21-15 This spark plug boot on an overhead camshaft engine has been
arcing to the valve cover causing a misfire to occur.

FIGURE 21-16 Measuring the resistance of a spark plug wire with a multimeter set to
the ohms position. The reading of 16.03 k(16.030 ohms) is okay because the wire is
about 2 feet long. Maximum allowable resistance for a spark plug wire this long would
be 20 k(20,000 ohms).

SPARK PLUG WIRE PLIERS ARE A GOOD

INVESTMENT
FIGURE 21-17 Spark plug wire boot pliers are a handy addition to any toolbox.

SPARK PLUG SERVICE

Spark plugs should be inspected when an engine
performance problem occurs and should be
replaced regularly to ensure proper ignition system
performance.
Many spark plugs have a service life of over 20,000
miles (32,000 kilometers).
Platinum-tipped original equipment spark plugs
have a typical service life of 60,000 to 100,000
miles (100,000 to 160,000 kilometers).


ROUTE THE WIRES RIGHT!
FIGURE 21-18 Always take the time to install spark plug wires back into
the original holding brackets (wiring combs).

SPARK PLUG SERVICE
FIGURE 21-19 When removing spark plugs, it is wise to arrange them so that they
can be compared and any problem can be identified with a particular cylinder.

SPARK PLUG SERVICE
FIGURE 21-20 A spark plug thread chaser is a low-cost tool that hopefully will not
be used often, but is necessary to clean the threads before new spark plugs are
installed.

SPARK PLUG SERVICE
FIGURE 21-21 Since 1991, General Motors engines have been equipped with slightly
(1/8 in. or 3 mm) longer spark plugs. This requires that a longer spark plug socket should
be used to prevent the possibility of cracking a spark plug during installation. The longer
socket is shown next to a normal 5/8 in. spark plug socket.

SPARK PLUG INSPECTION
Spark plugs are the windows to

the inside of the combustion
chamber.
A thorough visual inspection of
the spark plugs often can lead to
the root cause of an engine
performance problem.
Two indications on spark plugs
and their possible root causes in
engine performance include the
following:
Carbon fouling.
Oil fouling.

FIGURE 21-22 An extended-reach spark

plug that shows normal wear. The color
and condition indicate that the cylinder is
operating correctly.
FIGURE 21-23 Spark plug removed from an engine after a 500-mile race. Note the clipped
side (ground) electrode. The electrode design and narrow (0.025 in.) gap are used to ensure
that a spark occurs during extremely high engine speed operation. The color and condition of
the spark plug indicate that near-perfect combustion has been occurring.

FIGURE 21-24 Typical worn spark plug. Notice the rounded center electrode.
The deposits indicate a possible oil usage problem.

FIGURE 21-25 New spark plug that was fouled by a too-rich air-fuel mixture. The
engine from which this spark plug came had a defective (stuck partially open)
injector on this one cylinder only.

QUICK AND EASY SECONDARY IGNITION TESTS
FIGURE 21-26 A water spray

bottle is an excellent diagnostic
tool to help find an intermittent
engine miss caused by a break
in a secondary ignition circuit
component.


IGNITION TIMING
Generally, for testing,
engines must be at idle with
computer engine controls
put into base timing, the
timing of the spark before
the computer advances the
timing.
Pretiming Checks
Timing Light Connections
Determining Cylinder 1
Checking or Adjusting
Ignition Timing
FIGURE 21-27 Typical timing marks. The

numbers of the degrees are on the
stationary plate and the notch is on the
harmonic balancer.
IGNITION TIMING
FIGURE 21-28 Cylinder 1 and timing mark location guide.


IGNITION TIMING
FIGURE 21-29 (a) Typical SPOUT connector as used on many Ford engines equipped with
distributor ignition (DI). (b) The connector must be opened (disconnected) to check and/or
adjust the ignition timing. On DIS/EDIS systems, the connector is called SPOUT/SAW
(spark output/spark angle word).

SCOPE-TESTING THE IGNITION SYSTEM
Firing Line
Spark Line
Intermediate Oscillations
Transistor-On Point
Dwell Section
Pattern Selection
Superimposed.
Raster (stacked).
Display (parade).
Reading the Scope on Display (Parade)

Reading the Spark Lines

Spark Line Slope

Reading the Intermediate Section
Electronic Ignition and the Dwell Section
Dwell Variation (Distributor Ignition)
Coil Polarity
Acceleration Check
Rotor Gap Voltage


FIGURE 21-30 Typical engine analyzer hookup that includes a scope display. (1)
Coil wire on top of the distributor cap if integral type of coil; (2) number 1 spark
plug connection; (3) negative side of the ignition coil; (4) ground (negative)
connection of the battery.

FIGURE 21-31 Clip-on adapters

are used with an ignition system
that uses an integral ignition coil.


FIGURE 21-32 Typical secondary ignition oscilloscope pattern.


FIGURE 21-33 A single cylinder

is shown at the top and a 4cylinder engine at the bottom.


FIGURE 21-34 Drawing shows what is occurring electrically at each part of

the scope pattern.

FIGURE 21-35 Typical secondary ignition pattern. Note the lack of firing
lines on the superimposed pattern.

FIGURE 21-36 Raster is the best scope position to view the spark lines of all the
cylinders to check for differences. Most scopes display cylinder 1 at the bottom.
The other cylinders are positioned by firing order above cylinder 1.

FIGURE 21-37 Display is the only position to view the firing lines of all cylinders.
Cylinder 1 is displayed on the left (except for its firing line, which is shown on the
right). The cylinders are displayed from left to right by firing order.

FIGURE 21-38 A downward-sloping spark line usually indicates high

secondary ignition system resistance or an excessively rich air-fuel mixture.

FIGURE 21-39 An upward-sloping spark line usually indicates a mechanical

engine problem or a lean air-fuel mixture.

FIGURE 21-40 The

relationship between the
height of the firing line and
length of the spark line can
be illustrated using a rope.
Because energy cannot be
destroyed, the stored
energy in an ignition coil
must dissipate totally,
regardless of engine
operating conditions.


SCOPE-TESTING A WASTESPARK IGNITION

SYSTEM
A handheld digital storage
oscilloscope can be used to
check the pattern of each
individual cylinder.
Some larger scopes can be
connected to all spark plug
wires and therefore are
able to display both power
and waste-spark
waveforms.

FIGURE 21-41 A dual-trace scope pattern

showing both the power and the waste spark
from the same coil (cylinders 1 and 6). Note that
the firing line is higher on the cylinder that is
under compression (power); otherwise, both
patterns are almost identical.
SCOPE-TESTING A COIL-ON-PLUG IGNITION

SYSTEM
On a coil-on-plug (COP)
type of ignition system,
each individual coil can be
shown on a scope and
using the proper cables and
adapters, the waveform for
all of the cylinders can be
viewed at the same time
FIGURE 21-42 A secondary waveform

of a Ford 4.6 liter V-8,showing three
sparks occurring at idle speed.

IGNITION SYSTEM DIAGNOSIS












SUMMARY
1. A thorough visual inspection should be performed
on all ignition components when diagnosing an
engine performance problem.
2. Platinum spark plugs should not be regapped after
use in an engine.
3. A secondary ignition scope pattern includes a firing
line, spark line, intermediate oscillations, and
transistor-on and transistor-off points.
4. The slope of the spark line can indicate incorrect
air-fuel ratio or other engine problems.

REVIEW QUESTIONS
1. Why should a spark tester be used to check for
spark rather than a standard spark plug?
2. How do you test a pickup coil for resistance and
AC voltage output?
3. What harm can occur if the engine is cranked or
run with an open (defective) spark plug wire?
4. What are the sections of a secondary ignition
scope pattern?
5. What can the slope of the spark line indicate about
the engine?

CHAPTER QUIZ
1. Technician A says that the firing line shows the
voltage that is required to fire the spark plug.
Technician B says that spark line shows the
duration of the spark inside the cylinder. Which
technician is correct?
a)
b)
c)
d)
Technician A only
Technician B only
Both Technicians A and B
Neither Technician A nor B


CHAPTER QUIZ
1. Technician A says that the firing line shows the
voltage that is required to fire the spark plug.
Technician B says that spark line shows the
duration of the spark inside the cylinder. Which
technician is correct?
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
2. Technician A says that a defective spark plug wire
can cause an engine miss. Technician B says that
a defective spark plug can cause an engine miss.
Which technician is correct?
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
2. Technician A says that a defective spark plug wire
can cause an engine miss. Technician B says that
a defective spark plug can cause an engine miss.
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
3. The _____ sends a pulse signal to an electronic
ignition module.
a)
b)
c)
d)
Ballast resistor
Pickup coil
Ignition coil
Condenser


CHAPTER QUIZ
3. The _____ sends a pulse signal to an electronic
ignition module.
a)
b)
c)
d)
Ballast resistor
Pickup coil
Ignition coil
Condenser


CHAPTER QUIZ
4. Typical primary coil resistance specifications
usually range from _____ ohms.
a)
b)
c)
d)
100 to 450
500 to 1,500
1 to 3
6,000 to 30,000


CHAPTER QUIZ
4. Typical primary coil resistance specifications
a)
b)
c)
d)
100 to 450
500 to 1,500
1 to 3
6,000 to 30,000


CHAPTER QUIZ
5. Typical secondary coil resistance specifications
a)
b)
c)
d)
100 to 450
500 to 1,500
1 to 3
6,000 to 30,000


CHAPTER QUIZ
5. Typical secondary coil resistance specifications
a)
b)
c)
d)
100 to 450
500 to 1,500
1 to 3
6,000 to 30,000


CHAPTER QUIZ
6. Technician A says that an engine will not start and
run if the ignition coil is tracked. Technician B says
that one wire of any pickup coil must be grounded.
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
6. Technician A says that an engine will not start and
run if the ignition coil is tracked. Technician B says
that one wire of any pickup coil must be grounded.
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
7. Technician A says that a GM HEI distributor rotor
can burn through and cause an engine miss during
acceleration. Technician B says that a defective
distributor cap can cause an engine miss during
acceleration. Which technician is correct?
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
7. Technician A says that a GM HEI distributor rotor
can burn through and cause an engine miss during
acceleration. Technician B says that a defective
distributor cap can cause an engine miss during
acceleration. Which technician is correct?
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
8. The secondary ignition circuit can be tested using
_____.
a)
b)
c)
d)
An ohmmeter
A test light
An ammeter
Both a and b


CHAPTER QUIZ
8. The secondary ignition circuit can be tested using
_____.
a)
b)
c)
d)
An ohmmeter
A test light
An ammeter
Both a and b


CHAPTER QUIZ
9. Two technicians are discussing a no-start
condition. During cranking, a magnet held over the
coil moves and the engine backfires at times.
Technician A says that a bad pickup coil or CKP
sensor is the most likely cause. Technician B says
that an open coil primary is the most likely cause.
a)
b)
c)
d)
Technician A only
Technician B only

CHAPTER QUIZ
9. Two technicians are discussing a no-start
condition. During cranking, a magnet held over the
coil moves and the engine backfires at times.
Technician A says that a bad pickup coil or CKP
sensor is the most likely cause. Technician B says
that an open coil primary is the most likely cause.
a)
b)
c)
d)
Technician A only
Technician B only

CHAPTER QUIZ
10. Which sensor produces a square wave signal?
a)
b)
c)
d)
Magnetic sensor
Hall-effect sensor
Pickup coil
Both b and c


CHAPTER QUIZ
10. Which sensor produces a square wave signal?
a)
b)
c)
d)
Magnetic sensor
Hall-effect sensor
Pickup coil
Both b and c



Ignition &amp; Injection Systems

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OBJECTIVES

After studying Chapter 21, the reader will be able to:

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

CHECKING FOR SPARK

Weak ignition coil

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

CHECKING FOR SPARK

2009 Pearson Higher Education, Inc.

CHECKING FOR SPARK

2009 Pearson Higher Education, Inc.

ELECTRONIC IGNITION TROUBLESHOOTING

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

IGNITION COIL TESTING USING AN OHMMETER

To test the secondary coil winding resistance, follow

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

IGNITION COIL TESTING USING AN OHMMETER

FIGURE 21-3 Checking an ignition coil

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

PICKUP COIL TESTING

Automotive Fuel and Emissions Control Systems, 2/e

FIGURE 21-4 Measuring the resistance of an

TESTING MAGNETIC SENSORS

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

TESTING MAGNETIC SENSORS

FIGURE 21-5 An AC voltage is

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

TESTING HALL-EFFECT SENSORS

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

TESTING HALL-EFFECT SENSORS

FIGURE 21-6 (a) The connection

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

TESTING OPTICAL SENSORS

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BAD WIRE? REPLACE THE COIL!

2009 Pearson Higher Education, Inc.

TESTING FOR POOR PERFORMANCE

Automotive Fuel and Emissions Control Systems, 2/e

FIGURE 21-9 A length of vacuum hose being

TESTING FOR POOR PERFORMANCE

FIGURE 21-10 Using a

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

TESTING FOR A NO-START CONDITION

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

FIGURE 21-11 The firing order is

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SECONDARY IGNITION INSPECTION

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

SECONDARY IGNITION INSPECTION

2009 Pearson Higher Education, Inc.

SECONDARY IGNITION INSPECTION

FIGURE 21-13 Carbon track in

Automotive Fuel and Emissions Control Systems, 2/e

Ignition & Injection Systems

Ignition & Injection Systems