WARNING: Your vehicle has a high energy microprocessor controlled ignition system (HEISS). Approximately 40,000 volts are applied to the high voltage wires. Although the current is not life-threatening at low levels, a possible electric shock while testing the ignition system can cause serious consequences.
Therefore, if you handle a high-voltage wire with the ignition on, use a thick rubber glove or, as a last resort, pliers with insulated handles.
HELPFUL TIP: Before checking the ignition system, place the gear shift lever in neutral and leave the parking brake on.
1. With the ignition off on a 1.6L engine (VCT), check the integrity and fit of the high-voltage wires in the ignition coil sockets..
2….and on engines with a volume of 2.0; 2.3 and 2.5 l – seating of ignition coils on spark plugs.
3. Check the ignition coil for proper operation (see Checking the ignition coil).
4. If the ignition coil low voltage circuit is OK, check for spark at the spark plugs. On a 1.6L (VCT) engine, remove the high voltage wire from any spark plug…
5….and on 2.0 engines; 2.3 and 2.5 l remove the ignition coil. Insert a spare spark plug into the wire tip or into the ignition coil tip and press its metal part to the vehicle "ground" (for example, to the powertrain suspension support). Ask an assistant to turn the engine crankshaft with the starter.
WARNINGS: Reliable contact of the spark plug body with the "ground" is mandatory, since if an additional spark gap appears, larger than the gap between the spark plug electrodes, damage to the engine control unit or the high-voltage circuit of the ignition coil may occur.
Perform the specified check for no more than five seconds, so as not to damage the exhaust gas neutralizer if gasoline that has not burned in the engine cylinders gets into it.
6. If there is no spark, on 2.0 engines; 2.3 and 2.5 l replace the ignition coil (see Removing and installing ignition coils for duratec-he and duratec-v15 engines), and on a 1.6L engine (VCT), replace the high-voltage wires with new ones. You can first try to install non-new, but tested ones, from a "working" car.
7. If after replacing the wires the spark does not appear, replace the ignition coil (see Removing and installing the ignition coil of the 1.6L Duratec TI-VCT engine). If there is a spark, but the engine does not start, replace the spark plugs with new ones. You can also try to install not new, but tested ones from a "working" car.
8. If the engine still does not start, check the engine management system (see Fuel injection system faults).
The original article is available on the website FORDBOOK.RU