B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 013-012   Ignition Coil (Non Shielded)

CAUTION  Do not attempt to adjust the ignition coil tester. It is preset and not adjustable. An attempt to adjust can result in tool damage.

Use Ignition Coil Test Kit, Part Number 3164486.

Disconnect the spark plug wire from the ignition coil.

Firmly snap the right-angle (90-degree) end of the ignition coil tester onto the ignition coil terminal.

Attach the alligator clip to a suitable ground.

Route the ignition coil tester so that it does not touch any metallic surface on the engine, because arcing can occur.

Crank the engine or start the engine and let it idle.

Observe the spark gap inside the observation window. If a steady spark is observed, the ignition coil is acceptable; if no spark is observed, replace the ignition coil and test again.

Stop the engine.

Remove the ignition coil tester from the ignition coil and disconnect the alligator clip.

Connect the spark plug wire onto the ignition coil.

Repeat for the remaining ignition coils.

CAUTION  Do not attempt to adjust the ignition coil tester. It is preset and not adjustable. An attempt to adjust can result in tool damage.

Use Ignition Coil Test Kit, Part Number 3164486.

Remove the ignition coil.

Connect the ignition harness to the ignition coil. Insert the bare thread of the ignition coil tester into the end of the ignition coil.

Attach the alligator clip to a suitable ground.

Route the ignition coil tester so that it does not touch any metallic surface on the engine, because arcing can occur.

CAUTION  Angled connector coils must not be held vertical by holding the coil when testing.

Holding the connector coil by the ignition harness is acceptable.

Crank the engine or start the engine and let it idle.

Observe the spark gap inside the observation window. If a steady spark is observed, the ignition coil is acceptable; if no spark is observed, replace the ignition coil and test again.

Stop the engine.

Remove the ignition coil tester from the ignition coil and disconnect the alligator clip.

Install the ignition coil.

Repeat for the remaining ignition coils.

WARNING  The ignition system produces high voltage. To reduce the possibility of personal injury from electrical shock, do not touch any ignition wires or components while the engine is operating. Always use suitably insulated tools.

Disconnect the spark plug wires. Refer to Procedure 013-014 in Section 13.

Disconnect the ignition wiring harness.

Remove the capscrews that secure the ignition coil pack to the intake manifold cover.

Remove the coil pack.

WARNING  The ignition system produces high voltage. To reduce the possibility of personal injury from electrical shock, do not touch any ignition wires or components while the engine is operating. Always use suitably insulated tools.

Disconnect the ignition wiring harness from the ignition coil.

Remove the ignition coil from the bracket. Remove the ignition coil by pulling directly upward.

Do not force the ignition coil back and forth during removal. This can cause damage to the spark plug,, spark plug boot, or ignition coil.

Inspect the ignition coil pack for cracks, corrosion, connector pin damage, and damage to the potting.

Inspect the coil body for cracks, corrosion, and connector pin damage.

Replace the coil if damage is found.

Inspect the coil extension for cracks, corrosion, and connector pin damage.

Replace the coil extension if damage is found. Refer to Procedure 013-050 in Section 13.

NOTE: This step does not apply to the ISB5.9 G engine.

Measure the secondary winding resistance to check for open circuits. Connect the digital multimeter leads between pin 4 of the 4-pin coil connector and each of the three high-voltage towers of the ignition coil pack. The resistance measured must be less than 10k ohms.

If the resistance is not less than 10k ohms, then the ignition coil has an open secondary winding or coil, and must be replaced.

Replace the ignition coil pack as necessary.

NOTE: This step applies to the ISB5.9 G engine only.

Measure the primary winding resistance. Connect the digital multimeter to pin A and check the resistance to pin C, pin D, and pin E.

The primary winding resistance must be less than 2 ohms.

Measure the secondary winding resistance. Connect the digital multimeter to pin F and each of the three high-voltage towers.

The secondary winding resistance must be less than 10k ohms.

Replace the ignition coil pack as necessary.

Measure the secondary winding resistance to check for open circuits. Connect the digital multimeter leads between the 4-pin coil connector and the spark plug connection.

The resistance measured must be less than 20k ohms.

NOTE: Only remove the coil extension if the measured resistance is not less than 20k ohms.

If the resistance is not less than 20k ohms, remove the coil extension and test the coil again.

If the resistance is not less than 20k ohms, replace the entire coil.

If the resistance is now less than 20k ohms, replace only the coil extension. Refer to Procedure 013-050 in Section 13.

Replace the ignition coil as necessary.

Install the coil pack on the intake manifold cover.

Install and tighten the capscrews.

Install the spark plug wires. Refer to Procedure 013-014 in Section 13.

Connect the ignition wiring harness to the coil packs. Verify that the connectors snap and lock onto the coil packs.

CAUTION  Do not clean boots on an ISL G application. These boots are pre-greased.

CAUTION  The ignition coils must be installed individually to the coil brackets already mounted on the engine. Failure to do so can damage the ignition coil, spark plug boot, or spark plug.

A new boot must be installed when new spark plugs are installed, or when the boot has been damaged during removal.

Carefully align the opening in the spark plug boot with the top of the spark plug.

Press the coil down onto the spark plug until the coil mounting holes align with the mounting slots in the coil bracket.

Install the mounting hardware.

Tighten the fasteners.

Connect the ignition wiring harness to the ignition coil.

If there is difficulty installing the ignition coil onto the spark plug, the following suggestions may be helpful:

• Verify that the angle the coil is being installed is approximately 30 degrees from vertical and similar to the angle of the coil bracket or the angle of the other coils that are already installed.
• Position the spark plug boot on the ignition coil against the cylinder head in the spark plug well prior to pushing down on the ignition coil.