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Old 08-04-2017, 06:21 PM   #1
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Cracked Ignition Coil

So I got CEL code indicating misfire on cylinder 4, and the car was hesitating on low RPM under load.

I had replaced all the ignition coil less than 1000 miles ago with Beru coils. I pulled the one from cylinder 4 out, and saw that it was cracked badly!

I replaced it, and the car runs fine now. But I was wondering what might cause this...just a defect, or is there a root cause that I should look into?



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Old 08-04-2017, 07:14 PM   #2
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Yikes! Is that the new bigger style? I bought a set a year ago and haven't put them in yet...
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Old 08-04-2017, 08:59 PM   #3
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[QUOTE=stanigu;546128]So I got CEL code indicating misfire on cylinder 4, and the car was hesitating on low RPM under load.

I had replaced all the ignition coil less than 1000 miles ago with Beru coils. I pulled the one from cylinder 4 out, and saw that it was cracked badly!

I replaced it, and the car runs fine now. But I was wondering what might cause this...just a defect, or is there a root cause that I should look into?



Hard to tell from your picture, but that kinda looks like it was not seated properly on the plug then tightened down with the plug hard against the edge of the extension opening and the localized pressure caused the fracture. Is the extension straight or bowed? and is there any indentation at the point of the crack? Anyway that appears to be a stress fracture and not a defect. My .02.

Last edited by 911monty; 08-04-2017 at 09:17 PM.
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Old 08-04-2017, 09:18 PM   #4
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Wow, I have never seen anything like that. Cracks in coils are usually hairline cracks - that looks like the Grand Canyon in comparison.

Can you post another photo that shows the tube portion of the coil in clear focus so we can see the detail of the crack itself?
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Old 08-05-2017, 07:25 AM   #5
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That looks like installer error more than a part defect. It looks like the tear is from twisting so it was probably not seated properly and no dielectric grease used and it tore when tightening down.
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Old 08-05-2017, 07:38 AM   #6
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My same question - are those the updated thicker body coil packs?
I replaced mine about a year ago with the thicker body type. I felt they never did seat well. I felt I could have continued to tighten the bolts but I stopped when they were sufficiently tight enough using handheld hex wrench

Now I think I need to pull them out and examine them
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Old 08-05-2017, 07:15 PM   #7
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Installer error is a definite possibility, since I was the one who did the work (late at night too, I might add). And Cylinder 4 is the one that is tucked away towards the front with that dang hose getting in the way.

They are indeed the new "thick" variety. I'm surprised that the car ran at all with that huge crack. The only noticeable problem with the performance was at low RPM at high load.
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Old 08-05-2017, 07:36 PM   #8
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Quote:
Originally Posted by thstone View Post
Wow, I have never seen anything like that. Cracks in coils are usually hairline cracks - that looks like the Grand Canyon in comparison.

Can you post another photo that shows the tube portion of the coil in clear focus so we can see the detail of the crack itself?
For your viewing pleasure (viewer discretion advised....)


[IMG][/IMG]

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