DURASPARK TROUBLESHOOTING
Contents
1. 3 Measure ballast resistor between BATT terminal of ignition coil connector and wiring harness connector mating with RED module wire 4 Reconnect all connectors TEST RESULT TEST RESOLUTION 0 8 to 1 6 ohms Less than 0 8 or greater than 1 6 ohms Problem is either intermittent or not in ignition system Refer to Intermittent Diagnosis or return to Section 2 Diagnostic Routines Replace ballast resistor IGNITION SWITCH IGNITION MODULE NOTE WIRE SEQUENCE PURPLE ASIDA 15 26 ignition Systems Timing Procedures and Diagnostics p A Part 2 Test 5 TEST EQUIPMENT VOM STRAIGHT PINS TEST PROCEDURE 1 Remove SPARK TESTER reconnect coil wire to distributor cap 2 If starter relay has terminal disconnect cable from starter relay to starter motor 3 If starter relay does not have terminal 4 Supply Voltage Circuits TEST RESULT TEST RESOLUTION Test result OK Go to Part 2 Test 6 90 percent of battery volt age or greater Less than 90 percent of battery voltage disconnect wire to S terminal of starter relay Carefully insert small straight pins in RED and WHITE module wires Refer to vehicle wiring diagram Inspect wiring harness and connector s in faulty circuit s Worn or damaged ignition switch Refer to Shop Manual Group 33 Radio interference capac2. CABLE TO 4 EXP CYLINDER DO NOT USE SILICONE COMPOUND ON MULTIPOINT ROTOR 15 24 Ignition Systems Timing Procedures and Diagnostics TS Part 2 TEST EQUIPMENT VOM STRAIGHT PIN TEST RESULT TEST RESOLUTION 90 percent of Go to Part 2 Test 4 Refer to vehicle wiring diagram Inspect wiring harness between module and ignition switch Worn or damaged ignition switch Refer to Shop Manual Group 33 TEST PROCEDURE Turn ignition switch Off battery 1 Carefully insert small straight pin in RED voltage or module wire greater CAUTION Do not allow straight pin to contact electrical ground Less than 90 percent of battery voltage 2 Attach negative VOM lead to distributor base 3 Measure battery voltage 4 Measure voltage at straight pin with ignition switch in Run position 5 Turn ignition switch to Off position 6 Remove straight pin o BALLAST iGuition RESISTOR SWITCH oe g IGNITION IGNITION cot MODULE NOTE WIRE SEQUENCE HAS BEEN ARRANGED DISTRIBUTOR TO SIMPLIFY SCHEMATIC 3 ignition Systems Timing Procedures and Diagnostics 18 25 Part 2 Ballast Resistor Test 4 TEST EQUIPMENT VOM TEST PROCEDURE 1 Separate and inspect ignition module two wire connector with RED and WHITE wires 2 Disconnect and inspect ignition coil connector
3. F ignition Systems Timing Procedures and Diagnostics 15 21 SR RS a PE ET Preliminary Checkout Equipment amp Notes CHECKOUT Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected Examine all wiring harnesses and connectors for insulation damage burned overheated loose or broken conditions Be certain the battery is fully charged All accessories should be Off during diagnosis EQUIPMENT Obtain the following test equipment or an equivalent Spark Tester Special Service Tool D81P 6666 A See note Digital Volt Ohmmeter Rotunda 014 00407 12 Volt Test Light Small straight pins 2 NOTES All wire colors referred to in this part relate to the colors of the ignition module wires When working with a wiring harness the wires must be traced back to the ignition module for proper color identification When instructed to inspect a wiring harness both a visual inspection and a continuity test should be performed When making measurements on a wiring harness or connector it is good practice to wiggle the wires while measuring A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results 15 22 ignition Systems Timing Procedures and Diagnostics Part 2 Start Circuits Test 1 TEST EQUIPMENT SPARK TESTER VOM TEST PROCEDU
4. RE TESTRESULT TEST RESOLUTION No Sparks 1 Connect spark tester between ignition coil wire and engine ground 2 Crank engine using ignition switch Measure resistance of ignition coil wire Replace if greater than 7 000 ohms per foot Inspect ignition coil for damage carbon tracking e Crank engine to verify distributor rotation Refer to Shop Manual Group 23 and service as required Go to Part 2 Test 5 TO IGNITION COIL SPARK TESTER Ignition Systems Timing Procedures and Diagnostics 15 23 Part 2 Test 2 Run Circuits TEST RESULT TEST RESOLUTION No Sparks 1 Turn ignition switch from Off to Run to Off position several times 2 Spark should occur each time switch goes from Run to Off position 3 Remove spark tester reconnect coil wire to distributor cap Inspect distributor cap adapter rotor for cracks carbon tracking lack of silicone compound e Check for roll pin securing armature to sleeve in distributor Check that ORANGE and PURPLE wires not crossed between distributor and ignition moduie e If ignition module has Basic Part No 12A244 Go to the Spark Timing section to check spark retard operation COAT COMPLETE SURFACE OF ROTOR BLADE TIP WITH SILICONE COMPOUND 1132 THICK Go to Part 2 Test 3 NO COMPOUND ON THIS SURFACE 6 AND 8 CYLINDER ESCORT LYNX APPLI
5. ff position 8 volts IGNITION SWITCH La IGNITION IGNITION COIL MODULE NOTE WIRE SEQUENCE DISTRIBUTOR HAS BEEN ARRANGED BUT TO SIMPLIFY pS B SCHEMATIC ignition Systems Timing Procedures and Diagnostics 15 29 Distributor Stator Assembly and Wiring Harness TEST RESULT TEST RESOLUTION 400 to 1 300 Test result OK ohms Go to Part 2 Test 8 TEST PROCEDURE 1 Separate ignition module four wire connector Inspect for dirt corrosion and damage 2 Measure stator assembly and wiring harness Less than Go to Part 2 Test 11 resistance between wiring harness terminals 400 or mating with ORANGE and PURPLE module greater than wires 1 300 ohms NOTE Wiggle wires in wiring harness when measuring BALLAST RESISTOR IGNITION MODULE IGNITION COIL NOTE WIRE SEOUENCE HAS BEEN ARAANGEO DISTRIBUTORA TO SIMPLIFY SCHEMATIC 15 30 Ignition Module to Distributor Stator Assembly Wiring Harness Ignition Systems Timing Procedures and Diagnostics Part 2 Test 8 TEST EQUIPMENT VOM TEST PROCEDURE Attach one VOM lead to distributor base Alternately measure resistance between wiring harness terminals mating with ORANGE and PURPLE module wires and ground 3 Reconnect four wire connector p TEST RESULT TEST RESOLUTION Greater than e Test re
6. itor on ignition coil CAUTION Do not allow straight pins to contact electrical ground Measure battery voltage 6 Following table below measure voltage at points listed with ignition switch in position shown NOTE Attach negative VOM lead to distributor base e Wiggle wires In wiring harness when measuring IGNITION WIRE SWITCH TEST TERMINAL CIRCUIT POSITION BATT BALLAST TERMINAL RESISTOR START IGNITION COIL BYPASS Turn ignition switch to Off position Remove straight pins Reconnect any cables wires removed from Starter relay ooN ignition Systems Timing Procedures and Diagnostics 45 27 EL ET TSR EA STH Supply Voltage Circuits Part 2 Continued TO BATTERY Baas TT BALLAST RESISTOR m e IGNITION MODULE NOTE WIRE SEQUENCE HAS BEEN ARRANGED TO SIMPLIFY SCHEMATIC DISTRIBUTOR 18 28 ignition Systems Timing Procedures and Diagnostics Part 2 Ignition Coil Supply Voltage psu Test 6 TEST EQUIPMENT VOM TEST PROCEDURE Attach negative lead of VOM to distributor base TEST RESOLUTION e Go to Part 2 Test 7 6 to 8 volts TEST RESULT 2 Tum ignition switch to Run position Less than 6 Go to Part 2 Test 12 3 Measure voltage at BATT terminal of ignition volts or coil greater than 4 Tum ignition switch to O
7. m coil 5 i 2 Connect one lead of VOM to distributor base 3 Measure resistance between TACH terminal of ignition coil connector and ground 4 Reconnect ignition module and coil connectors 100 ohms or less e Inspect wiring harness between ignition module and coil Rae IGNITION IGNITION MODULE NOTE WIRE SEQUENCE HAS BEEN ARRANGED DISTRIBUTOR TO SIMPLIFY SCHEMATIC DISTRIBUTOR E BASE asas ignition Systems Timing Procedures and Diagnostics 15 33 ame Part 2 Distributor Stator Assembly psu Test 11 400 to 1 000 ohms TEST PROCEDURE 1 Separate distributor connector from harness Inspect for dirt corrosion and damage 2 Measure stator assembly resistance across ORANGE and PURPLE wires at distributor connector Test result OK Inspect wiring harness between distributor and ignition module 3 Reconnect distributor and module Less than e Replace stator assembly connectors 400 or greater than 1 000 ohms IGNITION MODULE NOTE WIRE SEQUENCE HAS BEEN ARRANGED TO SIMPLIFY SCHEMATIC Ignition Systems Timing Procedures and Diagnostics Part 2 Test 12 Ignition Coil Primary Resistance TEST EQUIPMENT VOM TEST RESOLUTION Test result OK 4 Disconnect ignition coil connector e Go to Part 2 Test 13 2 Measure primary resistance from BATT to TACH terminal 3 Recon
8. n module BLACK wire Go to Part 2 Test 15 CAUTION Do not allow straight pin to contact electrical ground Attach negative VOM lead to distributor base Turn ignition switch to Run position Measure voltage at BLACK wire Turn ignition switch to Off position Remove straight pin 0 5 volt or e Replace ignition module less BALLAST RESIST IGNITION CAAA SWITCH IGNITION com IGNITION MODULE NOTE WIRE SEQUENCE HAS BEEN ARRANGED DISTRIBUTOR TO SIMPLIFY SCHEMATIC DISTRIBUTOR Base 463704 Systems Timing Procedures and Diagnostics Distributor Ground Circuit Part 2 Continuity Test 15 TEST EQUIPMENT VOM TEST PROCEDURE TEST RESULT TEST RESOLUTION F 1 Separate distributor connector from harness Less than Test result OK Inspect for dirt corrosion and damage one ohm Inspect wiring harness and 2 Attach one lead of VOM to distributor base connectors between 3 Measure resistance by attaching other VOM distributor and ignition lead to BLACK wire in distributor connector module NOTE Wiggle distributor grommet when Greater than Inspect ground screw in measuring one ohm distributor 4 Reconnect distributor connector SOLLAR IGNITION vv SWITCH IGNITION 1OMTION MODULE NOTE YARE SEON MAS BEEN A ARRANGED TO SIMPLI SCHEMATIC
9. nect ignition coil connector Less than 0 8 or greater than 1 6 ohms e Replace ignition coil BALLAST RESISTOR IGNITION SWITCH IGNITION MODULE NOTE WIRE SEQUENCE HAS BEEN ARRANGED TO SIMPLIFY SCHEMATIC DISTRIBUTOR 6368 8 ignition Systems Timing Procedures and Diagnostics 15 35 Part 2 Test 13 TEST EQUIPMENT VOM STRAIGHT PIN TEST RESULT TEST RESOLUTION Greater than Go to Part 2 Test 14 1 5 volts 1 5 volts or Inspect wiring harness and less connectors between ignition module and coil Primary Circuit Continuity TEST PROCEDURE 1 Carefully insert small straight pin in module GREEN wire CAUTION Do not allow straight pin to contact electrical ground Attach negative VOM lead to distributor base Turn ignition switch to Run position Measure voltage at GREEN module wire Turn ignition switch to Off position Remove straight pin onbo m BALLAST RESISTOR IGNITION og SWITCH IGNITION com IGNITION MODULE NOTE WIRE SEQUENCE SCHEMATIC DISTRIBUTOR BASE A6310A 15 36 Ignition Systems Timing Procedures and Diagnostics a S O Part 2 Ground Circuit Continuity Test 14 TEST EQUIPMENT VOM STRAIGHT PIN TEST PROCEDURE TEST RESOLUTION TEST RESULT Greater than 0 5 volt 1 Carefully insert smali straight pin i
10. sult OK 70 000 ohms e Go to Part 2 Test 9 Less than Inspect wiring harness 70 000 ohms between module connector and distributor including distributor grommet BALLAST RESISTOR IGNITION SWITCH IGNITION coll DISTRIBUTOR IGNITION MODULE NOTE WIRE SEQUENCE HAS BEEN ARRANGED TO SIMPLIFY SCHEMATIC DISTRIBUTOR T BASE ion Systems Timing Procedures and Diagnostics Part 2 Test 9 TEST EQUIPMENT VOM TEST PROCEDURE TEST RESULT TEST RESOLUTION 1 Disconnect and inspect ignition coil 7 700 to Test result OK 10 500 ohms e Go to Part 2 Test 10 connector and coil wire 2 Measure secondary resistance trom BATT Less than Replace ignition coil 7 700 ohms terminal to high voltage terminal 3 Reconnect ignition coil wire or greater than 10 500 ohms Ignition Coil Secondary Resistance IGNITION SWITCH BALLAST RESISTOR H IGNITION con IGNITION MODULE PURPLE NOTE WIRE SEQLENCE HAS BEEN ARRANGED TO SIMPLIFY SCHEMATIC DISTRIBUTOR ORANGE 15 32 r ignition Systems Timing Procedures and Diagnostics z f cm Part 2 Module to Coil Wire DS II Test 10 TEST EQUIPMENT VOM TEST PROCEDURE TEST RESULT Greater than 100 ohms TEST RESOLUTION Replace ignition module 1 Separate and inspect ignition module four wire connector and ignition coil connector fro
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