Coil pack caught fire

jrsride2002 · Feb 6, 2018

Yup, just as the title states it.
Pictures tell the tale, for the most part.

I JUST finished doing an alternator swap. Fired up the motor to see if it was a successful swap. It was. It took about 30 seconds to smell the burning electrical components.

I was on the passenger side, front wheel, admiring my handy work. Then I got my first sent, of a problem. While I was dashing over to turn the engine off, I noticed a good size plum of white smoke coming from the driver side front wheel well. I cut the engine, pop the hood, and was in shock! Luckily, no actual flames.

I spent an hour trying to get the other half of the coil pack out of the cylinder... It's still stuck in there.

My options are limited, but that's my story of the day. Overall, I'm sure it was just a old pack. I have slowly been replacing all of the packs. Luckily, I already had the replacement on hand. But I still have to get the old one out, first.

~Junior

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jrsride2002 · Feb 7, 2018

Well, my connector looks great! That was a relief. It was a second thought, but worth the concern. Glad it worked out in my favor.

The other half of the plug is really in there. I have a pair of pliers, that I get a good bite with. But that beast just won't budge... Anyone have any ideas I can try? I need more leverage, but I'm not sure how to get it. I grab the lip of the coil stem (???), but all I can do is pull straight out. I'm just so limited.

TIA guys,
~ Junior

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mtnride · Feb 8, 2018

Could you possibly drill a hole in the top and put in a screw to be able to use a nail puller/pry bar. Looks like a tough one Junior!
Maybe some glue to make screw solid, good luck.

Built4Sin · Feb 8, 2018

mtnride said:
Could you possibly drill a hole in the top and put in a screw to be able to use a nail puller/pry bar. Looks like a tough one Junior!
Maybe some glue to make screw solid, good luck.

That sounds like it would work! Just be careful to not use too much, it kind off looks like the spark plug head in the middle. Might have to use JB weld and set a sacrificial socket in there to bond only to the outer ring of material left.

jrsride2002 · Feb 8, 2018

Thanks for the ideas guys!!

While I will try them out. Here's another question for you. What about removing the valve cover? Would that give me greater access, or more to work with?

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mtnride · Feb 8, 2018

Seems to me you have to remove coils and plugs to remove valve cover but I’ll check my Bentley Repair manual later and see what I can find

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mtnride · Feb 8, 2018

Built4Sin said:
That sounds like it would work! Just be careful to not use too much, it kind off looks like the spark plug head in the middle. Might have to use JB weld and set a sacrificial socket in there to bond only to the outer ring of material left.

By looking at what’s left of the coil, I think there is some room. I would guess the top of the spark plug terminates a little above the black knobs

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mtnride · Feb 8, 2018

Junior, another thought, as above drill hole but use lug nut cap removal tool, insert in hole and pull. Worst case the top of fried coil separates coil stem. You could probably grab coil stem with needlenose pliers at that point.
Let us know how it goes.

Spiegelglatt · Feb 8, 2018

Likely there is melted plastic that is bonding to the surround. Can it be forcefully twisted counter clockwise (so as to not damage spark plug threads?) perhaps the socket idea mentioned above with fast drying epoxy and an extension in the socket...then a ratchet with a beaker bar.

Breaking the outer bond of the melted material is the key you need to accomplished. Pulling straight out at first is just going to give you a good workout.

jrsride2002 · Feb 8, 2018

Spiegelglatt said:
Likely there is melted plastic that is bonding to the surround. Can it be forcefully twisted counter clockwise (so as to not damage spark plug threads?) perhaps the socket idea mentioned above with fast drying epoxy and an extension in the socket...then a ratchet with a beaker bar.

Iwas thinking the same, but was also thinking that if it doesn't work. Maybe the drill would be worth the effort. So I'll start with the drill, then try the socket.

Spiegelglatt said:
Breaking the outer bond of the melted material is the key you need to accomplished. Pulling straight out at first is just going to give you a good workout.

DUDE! You're telling me!!
I might not be that strong, but I found myself in a advantageous position with the extra leverage from my keg belly on the quarter panel. And it's still not enough?! I did some digging, and if all else fails. It'll be a new head. Those spark plug tubes, are NOT removable. So getting the valve cover off, then trying to pry the junk out COULD damage the tube. Which means a new head. The valve cover, is keeping the tube stabilized from being bent in a undesirable manor.
So if anyone sees this issue again, KEEP THE VALVE COVER ON. Or suffer the possibility of replacing the head.

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Spiegelglatt · Feb 9, 2018

Was also thinking a power tool like impact driver or even this (since there ain't much there not to hold onto

https://www.amazon.com/dp/B01BF0YXK6/ref=sspa_mw_detail_0?psc=1

Or perhaps an internal pipe wrench?

https://m.grainger.com/mobile/product/3ZG99?cm_mmc=PPC:+Google+PLA&s_kwcid=AL!2966!3!166589287111!!!g!71851510759!&ef_id=WPUJWgAAAkiy3pW6:20180209000014:s&kwid=productads-adid^166589287111-device^m-plaid^71851510759-sku^3ZG99-adType^PLA

Hard not seeing it in person, but sounds like you need some power help here...just don't go too crazy as you do not want to replace a head.

Cool heads prevail. Best of luck man, you got us cheering for you.

Spinnetti_ · Feb 9, 2018

Key on getting any packs out is rotation to break the seal... can you get it to rotate at all? once you do it should pop out.

jrsride2002 · Feb 9, 2018

As I was using a pick, to brake up the plastic guts. I realized that I screwed up, kind of in a big way. I didn't realize what I have been working on removing, until now. What I thought was the rest of the metal tube from the coil pack. Turns out to be the non-replaceable spark plug tube.

While I have damaged the spark tube, I THINK I can still get both the spark plug and coil pack in and out for future changes.

So, in the future. Tell the next person to make sure that they are NOT working on that spark plug tube.... Like I have been.....[emoji35] [emoji35] [emoji35] I am such a dumba** for not checking first... I just didn't think of it until now

~ Junior(Dumba**)

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Spiegelglatt · Feb 9, 2018

Ah, I see. Well the big test will be oil and even vacuum leaks. I would carefully reassemble drive a short distance and dismantle to check for leaking. Don't sweat it until you know if there is any damage, this kind of stuff happens to me all the time...I am like a bull in a China shop with most electrical connections for some reason...I swear I have sausage fingers..at least that is my excuse.

jrsride2002 · Feb 9, 2018

Right now, I am leaning heavily towards the drill and screw to pull the plug out. My new problem, is finding the damn charger for the drill battery!

I'll come up with something.

~ Junior

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jrsride2002 · Feb 10, 2018

A pilot hole, a wood screw, and some needle nose pliers.

So, due to the damage of the spark plug tube. It was more difficult to get the coil out. Just some more tugging, was all that was required.

So, if this happens to anyone else. DON'T START WITH PLIERS!!!
*Start with pulling the next plug, make sure you're looking at the correct object to damage(or not damage).
*Then use a straight pick, to see if the coil is bonded to the spark plug tube or not. If it's not moving, use the pick to scrap away material.
*Have a can(or three) of compressed air for cleaning the material out of the tube.
*Keep using the pick, until the coil breaks free and is able to spin in the tube.
*When the coil can spin 360*, grab a drill and wood screw.

Please guys, don't let someone else goof up the tube like did. Now, if I have a problem with the tube. I'll have to get a whole new head. Plane and simple.

Thanks for the help and ideas,
~ Junior

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FSJ Guy · Feb 10, 2018

Glad you got it out. Hopefully that sleeve isn't too damaged!

jrsride2002 · Feb 10, 2018

I won't lie. I had a pucker moment, when the broken coil didn't come out. For now, it all works. What I'm going to try next, is some kind of metal cone object. To round out that tube. Pulling on it with pliers, made it flat in some spots. Not to mention chewed up and rough.

I'm thinking maybe a cone plum weight??!?? Then some sandpaper to smooth out the inside of the tube.

~ Junior

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jrsride2002 · Feb 10, 2018

So I think Google found what I can use. "Solid metal cone shaped". It has a flat top, perfect for tapping it with a hammer. Widely available, and a very reasonable price. Can be found at most adult entertainment boutiques!

LoLoL
I can't believe it!!!! Would not have thought about it, but it would be perfect for my needs. ON THE ENGINE!

That's just damn funny to me,
~ Junior

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Coil pack caught fire

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