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Coil Packs (cars)

Black Hole

May contain traces of nut
What does the team think?:

I had 3 coil packs* (out of 4) fail within about 30 miles**, had all four replaced and my car has been fine since then (the fourth was replaced as a precaution, it could have failed any time).

[ * Actually coil-on-plug, but everyone seems to call them coil packs regardless. ** Firstly one failed, and I had that replaced individually and thought everything was fine, but then I had to abandon a journey the next day and limp back to my repair shop with two more cylinders misfiring! :mad: ]

To me, this seems like an unlikely coincidence. A coil pack is just a transformer (and perhaps a diode), taking a low voltage pulse in one end from the engine management computer (ECU), and outputting a HT pulse direct to the spark plug, one per cylinder. Saves all that messing around with distributors and HT leads.

The only point of commonality is the ECU, the coil packs seem to be independent of each other, so why should they fail as a batch? My mechanic says that's typical, and a friend who's worked in car sales agrees, but why???

I put the question on a car forum and the yobbos piled in like it was a stupid question – of course they're all the same age so they're all going to fail around the same time, like light bulbs. My arse. That just served to remind me why I don't spend time on car forums any more. There has to be a physical explanation. Idiots.

Bulbs have tungsten filaments, which gradually evaporate as a direct function of duty hours. Like black holes, once it has evaporated enough the filament goes into exponential run-away and the bulb blows. The service life is predictable. So where's the failure mechanism dictating the service life of a coil pack?

Even if there is a failure mechanism, the batch-failure implies a manufacturing tolerance of 0.01% (failing within 30 miles after 350,000 miles service). Really??

The alternative is some kind of feedback which causes a cascade failure, but I can't see where that is coming from either.
 
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I suppose it depends what the failure was. On my car after 12 years I replaced the coil pack due to mis-firing, this pack was a single pack with all four coils and connectors in one, so a pack in the real sense. One of the connectors had completely been destroyed by arcing due to a failure of a resistor at the top of the connector, and over time it got to a point it couldn't arc over enough to deliver a spark as the remaining spring and connector had essentially evaporated. As I removed the coil pack, two of the other connectors broke due to aged fragile plastic.

I wonder if in your case the mechanics had removed all the coils to check them to locate the fault, and given they were all of an age and so maybe fragile, the act of checking them caused a crack or damage that then led to a failure of them all quickly after?
 
I wonder if in your case the mechanics had removed all the coils to check them to locate the fault, and given they were all of an age and so maybe fragile, the act of checking them caused a crack or damage that then led to a failure of them all quickly after?
I would suspect this to be the case, the environment under the bonnet is one of the worst for temperature extremes, moisture extremes, and general vibration.

I think I am glad I drive a diesel ... :cool:
 
I wonder if in your case the mechanics had removed all the coils to check them to locate the fault, and given they were all of an age and so maybe fragile, the act of checking them caused a crack or damage that then led to a failure of them all quickly after?
Nope, I was watching. Just checked the diagnostics which cylinder it was, we discussed what it might be and he said try the easy thing first, walked across the yard to the factors and brought back a coil, fitted it and away. No other interference at all.
 
I think I am glad I drive a diesel ... :cool:
They have their own set of problems, such as the high pressure direct injectors. Good for some things, bad for others (such as not being able to stop a diesel engine in a combustible atmosphere, or if the piston rings get worn and it starts running on sump oil).
 
An example of cascade failure: I rode a push-bike while at university, and it had a dynamo (for the lights) integrated into the front wheel hub. I was out for a ride of a Saturday afternoon and it was getting dark, so I turned my lights on. I whizzed down a hill so fast that the over-voltage blew the rear lamp with a clear pop, promptly followed by the (much sturdier) front bulb when the reduced load sent the voltage even higher!

There I was in the unlit countryside, barely able to see where I was going and little choice than to get off and walk.
 
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