Why Do Ignition Coils Fail?
2 Answers
Because ignition coils are frequently exposed to high-temperature and high-pressure working conditions, they are prone to damage. Below is relevant information about ignition coils: 1. Working Principle: During engine operation, ignition coils often carry high-voltage pulse currents of tens of thousands of volts. Prolonged operation in high-temperature, dusty, and vibrating environments inevitably leads to aging or even breakage. 2. Composition: A typical ignition coil contains two sets of windings: the primary coil and the secondary coil. The primary coil uses thicker enameled wire, usually wound 200-500 turns with approximately 0.5-1 mm diameter wire; the secondary coil employs finer enameled wire, typically wound 15,000-25,000 turns with about 0.1 mm diameter wire.
There are actually quite a few reasons why ignition coils fail. The most common one is aging and leakage. Just think about it—after a car has run over a hundred thousand kilometers, high-voltage current is constantly jumping around inside, and the coil's insulation layer gradually cracks and leaks. Another reason is prolonged high-load operation, like frequent stop-and-go traffic or slow crawling, which causes the coil to be trapped near the engine and baked at high temperatures. When the temperature soars past 100 degrees, the insulation material becomes brittle. Loose wiring connections can also lead to poor contact, causing instant discharge and sparks that erode the internal copper wires. I've even seen cases where the coil connector melted. Sudden short circuits are another issue—oil or water seeping into the engine bay or messy aftermarket wiring can easily trigger a short circuit. It's best to regularly check the condition of the spark plugs. If the spark plug gap is too wide, it can cause a sudden surge in load during coil discharge, leading to premature failure.
