Different spark intensity

Tiny
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Then I will need a picture of your engine and we need to trace this hose to find where the other end attaches. The picture you attached has the hose coming out of the valve cover in the back drivers side corner of the engine. That matches the diagram that I attached which would be the PCV. Based on the information that you provided, I am not sure what else this would be. In order for me to help figure that out we are going to need more detail and pictures of your engine.
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Sunday, October 11th, 2020 AT 10:54 AM
Tiny
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Yes, it is that hose. I took the stock filter box and saw the hole on the side where it has been previously connected. I have glued a small pipe there with a silicone and these days going to mount stock filter box and connect that hose there and will see if there is some change. Until then I would like to ask one more question, about the speedometer, does someone have an idea what can cause the problem.
The problem is: When you drive, the needle meter show the correct speed, but the digital meter show incorrect numbers. For example you drive 50kmh, and numbers say 40. When you stop, needle goes to 0, and digital numbers stuck to some value as 15 kmh or 20-25 kmh.
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Tuesday, October 13th, 2020 AT 12:31 AM
Tiny
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We can definitely help with that issue. however, we need to start a new post because we need to keep each one to one topic. If others look for the solution then they will not find the solution under different topics.

https://www.2carpros.com/questions/new
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Tuesday, October 13th, 2020 AT 6:25 PM
Tiny
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Tonight I made another check, as I told, I removed the electrical connectors from dpfe sensor and vacuum switch solenoid of EGR valve, and also blocked the hoses, but as I saw the vacuum switch was bad and there was a vacuum leak. After I unplug its main hose and blocked it, I saw a new problem, when driving in idle, it fluctuates a lot.
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Friday, October 16th, 2020 AT 3:33 PM
Tiny
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Okay. I think at this point we are into new issues that we need to start fresh simply so that others will benefit as well from seeing this solution. This is not related to a weak spark so we need to start a new one and work through this issue. I will say that this sounds like a vacuum leak so the fact that you found one means there could be another.

So let's just get this started and we can work through it. Thanks

https://www.2carpros.com/questions/new
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Saturday, October 17th, 2020 AT 5:55 PM
Tiny
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Can someone give me diagram or words explanation about the wiring of the ignition coil pack to be able to try put some new wires? Or tell me if that is normal to have one weak spark and one strong on the same coil. Because I bought new ignition coil pack, cables are almost new (also tried with another set) and there is still weak spark on 1 and 2, and strong on 3 and 4. It is noticeable, because when cable is removed, on 1 and 2, spark starting to jump only on 1-2 cm away of spark plug and is almost not noticeable, what is not case on 3 and 4 where the spark jumps about 10 cm anywhere and is strongly noticeable. Thanks
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Monday, September 27th, 2021 AT 2:57 AM
Tiny
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The way this works is power (12 volts) is supplied to the coil through the violet and black wire. The fact that one side of the coil is fine and the other is not shows that this 12 volts is not the issue.

However, the coil then takes this 12 volts and when the signal is interrupted by the PCM it creates high voltage and sends this to the spark plugs.

What I would do is measure the resistance in the two wires coming from the PCM to the coil and make sure it is less then a half ohm in each wire.

You do this by disconnecting the circuit at the coil and PCM then set your meter on ohms and probe both ends of the circuit and see what the meter says.

Here is a guide that covers this.

https://www.2carpros.com/articles/how-to-use-a-voltmeter

If the wires both show less than a half ohm of resistance then more than likely the issue is in the PCM that is no interrupting the signal so you have 12 volts going to the plugs rather than the high voltage needed.

Take a look at the wiring diagrams below.

Thanks
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Monday, September 27th, 2021 AT 11:16 AM
Tiny
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Dear, thanks for your answer and for your diagrams. I am going to do the measurement tonight after work and give you a feedback answer. As I understand you, I should measure the resistance between the two (as I think ground) points that come from PCM, because the center wire is common + for both coils in the pack. Here I would ask you one (between) question. Can the ignition capacitor somehow affect the spark? Because as I can read on internet it is only for radio interference removal. And mine is removed, because when I bought the car, it's wire was cut and it was just screwed, so when I replace the coil pack, I dismounted it. I mean for this capacitor on the photo attached.
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Tuesday, September 28th, 2021 AT 4:41 AM
Tiny
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That is correct. Unhook the connector from the coil and PCM and put your leads on both ends of the wire and measure the resistance (ohms).

As for the capacitor, it would not cause this issue on just half of the plugs. It is there to reduce the "noise" on the circuit so that you get a good clean signal.

If yours is removed, it is a good idea to reinstall it, but I doubt that will fix this issue.

Take a look at the diagram and I marked on the diagram to try and help explain this.

Thanks
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Tuesday, September 28th, 2021 AT 11:59 AM
Tiny
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I thought that I should measure these two points as showed in attachment. But in this case as you attached, I should remove the PCM and measure the resistance from one wire end to other wire end as I can understand?
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Tuesday, September 28th, 2021 AT 12:18 PM
Tiny
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That is exactly correct. The way in which you are showing is testing the coil for an open circuit within the primary windings.

That is a good test, but I don't think that is your issue because you are getting spark on all four plugs just weak spark on two of them.

So that means either the new coil has an issue with the secondary wirings or the PCM is not opening that ground side to cause the field collapse for the voltage spike.

Basically I think you are going to have no issue with the wire and the PCM is just never opening the ground side when those plugs are supposed to fire so you never get the high voltage spike.

Clearly this is all going off the fact that you are seeing a weak spark.

With a new coil doing the exact same thing, either the spark is not weak or the PCM is not spiking the voltage.

Take a look at the info below.
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Tuesday, September 28th, 2021 AT 12:36 PM
Tiny
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Isn't there some measuring way to measure the voltage on primary windings? I mean easier way, because PCM as I know is very good hidden inside and to measure this resistance, I should unplug it and find the correct wires, because I should measure the resistances of both wires - for each coil because it gives low spark on both coils - one end strong one weak.
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Tuesday, September 28th, 2021 AT 12:42 PM
Tiny
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Mine case is like this:
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Tuesday, September 28th, 2021 AT 12:59 PM
Tiny
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I also found this on Google about that capacitor, is it true?
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Tuesday, September 28th, 2021 AT 2:20 PM
Tiny
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This is not true. The condenser or capacitor is only there to absorb excess current flow. It does not deliver high voltage or amplify it. That is solely done by the coil.

There are two main reasons for this part. First if there is excess current from other sources, it absorbs this current so that the signals are not interrupted.

The second is so that there is no arcing in the coil when the PCM interrupts it.

So now that I say this, how long did it take for the new coil to have a weak spark? I understood that it was immediate. Meaning you had weak spark, put the new coil on it and still had weak spark as soon as you started the engine.

If you have no capacitor then the coil will eventually fail because when the PCM interrupts the signal in order to create the high voltage, the current actually tried to jump across the coil and it can burn them up.

Normally this takes a little bit of time which is why I said it would not cause this. However, if you don't have one it may be the cause of the coils failing.
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Tuesday, September 28th, 2021 AT 5:25 PM
Tiny
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The weak spark was from the beginning of time using new coil pack. Also, as I mentioned, it is not weak spark from one coil, but weak spark from one side of both coils on the pack. As I mentioned before, weak on 1 and 2. Also I tried swap test, and when I swap the plug cables, I got weak sparks on 3 and 4, strong on 1 and 2.
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Tuesday, September 28th, 2021 AT 5:31 PM
Tiny
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Okay. So, I read back through this, and I want to confirm. You had the original coil on the vehicle, it had this same issue. Then you replaced it for this issue, and it still is the same?

I just want to double check that the coil was not replaced for another issue and now you have this issue on the replacement coil.

I am attaching a video on how to check the coil. This test is being done on a coil on plug style, but the idea is the same on your coil pack. Clearly, we are only going to have two to test rather than doing each individual.

https://youtu.be/1zQQy9noYQ0

The fact that you can swap the plugs around and it is still the same ports on the coil just shows that it is either the coil, wiring, or PCM.

We need to run through these tests but if the coil was replaced for this issue and the new coil is doing the same thing then I would replace the ECM or send it out and have the circuit board checked and repaired.
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Wednesday, September 29th, 2021 AT 3:15 PM
Tiny
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Car was bought in chaotic condition, but no one is guilty about my fault. It was bought with replaced engine. Now the engine is zetec 1.8, also it has added modified LPG (not one of new types with injectors) and also it has problems with driving and idle. I cleared the EGR valve, but it didn't help, so I completely remove it. Then it got better in driving, and not so stable idle. As I mentioned I also replace the IAC valve, but idle was the same. I found some vacuum leaks with a cigar smoke test and fixed them, so idle stabilized a little bit more. When you stop, it is high and slowly goes down, sometimes to 900, sometimes to 1,100. Sometimes it immediately stops on 1,000. The issue with the spark I noticed when was replacing spark plugs and wires. Then tried with other coil pack (not new) it was the same. Then bought new one and it was still the same and went to 7-8 mechanics here in our stupid Macedonia and everyone says When it has a spark, it is a spark, it works, and it drives, so it is completely okay. About the PCM must be honest that I don't have money to replace it. Also, as there is written it acts like a ground switch, so when it sends signal to both coils as I think it should be okay. Also, last night I found a little module under the hood on the driver side and googled its number, it shows cruising control module, so I plan to try unplugging and try to drive because maybe it causes unstable IAC work somehow. When you have million of issues you don't know where to start.
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Thursday, September 30th, 2021 AT 4:46 AM
Tiny
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Oh man. This is a much larger monster then I ever thought. So, what vehicle did this engine come out of and did you use the PCM out of that vehicle as well?

We have been working off a wiring diagram and information for the engine that came in this vehicle so looking at the correct engine diagram may change our direction.

Also, I just went back and watched that video. Can you get a clear picture or video of the plugs with the weak spark and see what the spark actually looks like? If it is blue, then just because it doesn't arc as far as the other side of the coil doesn't mean that it is causing the varying idle issue.

If that were a case, it would cause a misfire on those cylinders each time they fired. So, a ranging idle is due to the air fuel ratio not remaining stable. So that would be unmetered air due to a vacuum leak or leaking fuel injectors or pressure issues in the fuel system.

https://www.2carpros.com/articles/how-to-use-an-engine-vacuum-gauge

https://www.2carpros.com/articles/how-to-check-fuel-system-pressure-and-regulator

Let us know this info and we can go from there. Thanks
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Thursday, September 30th, 2021 AT 2:57 PM
Tiny
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I should make another video tomorrow if you like to see that clearly. About the engine, the seller (you can call him liar) told me that it is from Mondeo mk 2, but only that, nothing more. He even sold me it without real balance bar, as I was unable to notice. Even with no driver side window mechanism inside, telling me that the button doesn't work. As I read on internet that small module called cruising control, controls the throttle by a step motor or by the brake vacuum with a second wire (instead of that one from the pedal), so that's why I asked you would be some damage if I just unplug that piece to try to drive, because if that makes some vacuum changes maybe that causes something like leaking? Also, I read lot of texts about wasted spark ignition, and nowhere found about the intensity of the spark, but found that in these types of ignition coil packs, each coil has positive and negative side on the secondary, so in that case, can it be normal situation with the spark arch? Thanks, a lot for your patience and time.
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Thursday, September 30th, 2021 AT 3:12 PM

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