What Causes the Ignition Coil to Keep Failing?

[DelJaxson]

Ignition coils frequently fail due to the following reasons: 1. The thermal effect of current damages the insulation of the coil inside the ignition coil; 2. Design or manufacturing issues with batch spare parts, leading to ignition coil failure; 3. Engine overheating, causing the insulating varnish or adhesive of the coil to melt and fail; 4. Open circuit in the high-voltage line, leaving the generated high-voltage electricity with no path, which can easily cause the high-voltage coil to be punctured; 5. Excessive spark plug electrode gap, increasing the load on the ignition coil and causing the high-voltage coil to puncture, resulting in a short circuit or open circuit. Typically, an ignition coil contains two sets of coils: the primary coil and the secondary coil. The primary coil uses thicker enameled wire, usually around 0.5 to 1 mm in diameter, wound approximately 200 to 500 turns; the secondary coil uses finer enameled wire, usually around 0.1 mm in diameter, wound approximately 15,000 to 25,000 turns.