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Beru All-About-Ignition-Coils PDF
Beru All-About-Ignition-Coils PDF
Beru All-About-Ignition-Coils PDF
Technical
Information
No. 07
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2
Table of Contents
Introduction 3
Ignition coils –
design and mode of operation 5
Ignition technology terminology 6
How many ignition sparks does an engine need? 7
Ignition coil specifications / characteristics 7
Ignition coils –
types and systems 8
Canister-type ignition coils 8
Electronic distributor ignition coils 9
Double-spark ignition coils 9
Ignition coil rails 11
Plug shaft / plug / smart plug top coil ignition coils 11
Dual coil ignition coils 13
Workshop tips 17
Reasons for replacement 17
Professional removal / installation 18
Special tool for ignition coil replacement 18
Testing and checking 20
Step-by-step defect identification 21
Self-test 22
3
Introduction
or 200 mJ (future)
Vibration range to 55 g
primary winding
The quality of the iron core
N1 N2
E = Laminated iron core (magnetic)
N1 = Windings primary side 100–250 windings
on
on off
off
Ignition
on technology
time off
Charging time
Charging
terminology
Ignition
Ignition time
time
Control on Charge start
Chargingstart
Charge time off Energy storage: During current supply to the
Cut-offIgnition
current timeTime
Cut-off current Time coil, energy is being stored in the magnetic field.
Charge start
Charging time
Cut-offIgnition
current timeTime
Power on, coil is charged (primary circuit is
closed, secondary circuit is open). At a specified
Charge start
Cut-off current Time ignition point the current is interrupted.
Activation spark
Combustion duration
Combustion duration
7
Insulating cover
Housing
Secondary winding
Casting compound
Insulator
Iron core
9
Diagnostic possibilities
Ion current signal
Interference suppression
Power cut-off
BERU distributor ignition coil with
Current limitation built-on output stage for vehicles
Thermal cut-off
with mechanical ignition distributor.
Cylinder 3 C+
Ignition coil tower C
Double spark ignition coil Pos. spark
for 2 x 2 spark plugs.
For example, for:
Volkswagen, Audi. Cylinder 4 D+
Ignition coil tower D
Pos. spark
Cylinder 2 B-
Ignition coil tower B
Neg. spark
360° Kw
Point of time 1 2 3 4
Ignition cycle 1–3–4–2
Modular, compact, light smart plug top coil ignition coils of the
latest generation are especially suited with their space-saving
geometry for modern downsized engines. Even though they are
more compact than larger ignition coils, they generate greater
combustion energy and higher ignition voltage. Innovative plastics
and the extremely safe connection technology of the components
inside the ignition coil body also ensure an even greater reliabi-
lity and durability.
5 4 3
R= 2 kΩ + 10
– 20 %
15 4
Diode
Lp Ls
Rp Rs
1 31
Silicone high-voltage
spark plug connector
Primary connector
Interference-suppression
resistance Ground pin
Contact spring
Single spark ignition coils, for example for Audi, Porsche, VW.
The individual components are channeled into the line The winding of primary and secondary coils ...
at the respective stations.
… is executed and monitored by computers. This is where the primary and secondary coils are fully
automatically assembled.
The secondary wire is embedded in the casting resin by One of the most important steps in the production
vacuum casting. sequence: final inspection of the ignition coil.
15
Cheap copy: There are various Copy: Wires running in every which
foreign bodies in the coil (see arrow Solder splashes way, distorted contact fields in the
tips), which is evidence of question- high-voltage connection, crooked
able production quality. Depending coil bodies and boards: premature
the location, material and thickness, failure of the ignition coil is only a
these may subsequently result in matter of time.
short circuits and coil failure. Also
noticeable: a slipped or incorrectly
inserted component.
Copy: The high-voltage cable and Copy: Ignition coil housing and Copy: Separation between primary
iron core must have a secure high-voltage cable have been filled and secondary coil bodies due to
distance from the high voltage. In with gravel to save on expensive unoptimized material pairings. This
this case the high-voltage cable is casting compound. Air bubbles have can result in leakage currents and
too close to the iron core. Possible formed in the gaps, the impregna- disruptive discharge at the primary
consequences are high voltage tion quality suffers, especially in coil and thus lead to failure of the
flashover and thus total failure of the high-voltage section: If air coll- ignition coil.
the ignition coil. ects in the secondary winding, it
will become ionized – this means
the air becomes conductive and in
effect corrodes the coil housing
until a ground potential is reached.
This will result in a short circuit or
flash-over and failure of the ignition
coil.
17
Workshop tips
Contaminated surroundings
Ignition coils, which due to their installation position
frequently come into contact with spray water or road salt
are especially at risk. This exposure is exacerbated by the
use of engine cleaning with high pressure sprays. As a
result seals can be destroyed and contacts corroded.
Workshop tips
Workshop tips
Formation of longitudinal
cracks on coil body due
to incorrect and excessive
tightening torque of 15 Nm
instead of the correct 6 Nm.
The solution
Before the spark plug is installed, apply a thin layer of BERU
connector grease (order no. 0 890 300 029 with 10g or
0 890 300 045 with 50g) to the (smooth or fluted) spark plug
neck.
Important: always check the spark plug connector and, if
required, replace. Especially in the case of single and double The hairline cracks are clearly
visibly by pressing the spark
spark ignition coils with mounted connectors, it is recom-
plug connector.
mended to replace the connector along with the spark plugs
– as the latter often become embrittled in the sealing area of
the spark plug and thus become leaky.
Workshop tips
Workshop tips
Measure secondary
resistances of the ignition
coils with ohmmeter at the
high-voltage output. Outputs
cylinders 1+4 / outputs
cylinders 2+3. At 20 degrees
Celsius, the nominal resistance
must be 4.0–6.0 kΩ. If the
values are not reached, the
ignition coil must be replaced.
22
Self test
1. Which coil wire is thicker?
A. Coil wire on primary winding
B. Coil wire on secondary winding
7. What
number of cylinders is suited for double
spark ignition coils?
A. even number of cylinders
B. odd number of cylinders
23
Self test
8. Why is a high-voltage diode in the secondary
circuit required for single spark ignition coils?
ignition coils?
A. 5 mJ
B. 10 mJ
C. ca. 100 mJ
Solutions: 1A, 2C, 3B, 4A, 5A, 6C, 7A, 8A, 9C, 10 A, B, C.
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®
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