Blown Ignition Coil

[brimwin]

I just brought my 2000, 911 out of storage and ran great until it developed a definite misfire. Fault code 63 - "Cyl 1 misfire damaging to cat". Upon inspection, I found the coil to be blown out (melted plastic) on the connection side of the coil. I bought a new coil and the part number was 996 602 101 01 instead of the original 996 602 102 00, but was told this is the same coil, just different revision. Replaced coil and started car with durametric hooked up and cyl 1 was again misfiring, so I increased RPM and the misfire went away. I dropped back to idle, and just when I was thinking things were good, the engine made a bad noise and died. Many fault codes: All injector valve cylinders below limit, Heating power 02S ahead of cat bank 1 & 2, and P1571 code 39 Immobilizer. Again I found that the new ignition coil on cyl 1 was blown.

I'm thinking that it is not an ignition coil problem. Has anyone had a similar experience?

Thanks for any help,

Bill

[Loren]

I just brought my 2000, 911 out of storage and ran great until it developed a definite misfire. Fault code 63 - "Cyl 1 misfire damaging to cat". Upon inspection, I found the coil to be blown out (melted plastic) on the connection side of the coil. I bought a new coil and the part number was 996 602 101 01 instead of the original 996 602 102 00, but was told this is the same coil, just different revision. Replaced coil and started car with durametric hooked up and cyl 1 was again misfiring, so I increased RPM and the misfire went away. I dropped back to idle, and just when I was thinking things were good, the engine made a bad noise and died. Many fault codes: All injector valve cylinders below limit, Heating power 02S ahead of cat bank 1 & 2, and P1571 code 39 Immobilizer. Again I found that the new ignition coil on cyl 1 was blown.

I'm thinking that it is not an ignition coil problem. Has anyone had a similar experience?

Thanks for any help,

Bill

The latest coil pack for your car is: 997.602.107.00

What are all the current fault codes?

[brimwin]

Fault codes are:

1. 
   

153

62

63

66

150

152

155

151

154

13

5

14

4

39

[vizcarra44]

Fault codes are:

1. 
   

153

62

63

66

150

152

155

151

154

13

5

14

4

39

How does the wiring connector to the coils look? Melted, usually the fuse for dme or ignition blows, check your fuses. Does car start up at least? If you do have a blown fuse, you may have either a wiring issue or bad Dme caused by shorted coil taking out one or more drivers. :huh:

[wvicary]

I have seen coils damaged like this before but I believe it was from a faulty spark plug and never happened within minutes of replacement.

[dr914jr]

I just replaced all 6 of mine for kicks. I figured at 140k they deserved to retire.

[brimwin]

How does the wiring connector to the coils look? Melted, usually the fuse for dme or ignition blows, check your fuses. Does car start up at least? If you do have a blown fuse, you may have either a wiring issue or bad Dme caused by shorted coil taking out one or more drivers. :huh:

Wiring looks good. I did find that the 30A Ignition, Fuel Injection and Oxygen Sensor Heating fuse was blown. I guess that would account for the injector valve fault codes 150, 151, 152, 153, 154, 155, and heating power 02S faults 4, 5, 13, 14. Car does not start - which I assume is due to fault code 39 Immobilizer.

How do I check for a bad DME? I hate to put in another new ignition coil and have it blow, or could it be due to the old revision ignition coil that I put in after the original coil blew?

[brimwin]

I just brought my 2000, 911 out of storage and ran great until it developed a definite misfire. Fault code 63 - "Cyl 1 misfire damaging to cat". Upon inspection, I found the coil to be blown out (melted plastic) on the connection side of the coil. I bought a new coil and the part number was 996 602 101 01 instead of the original 996 602 102 00, but was told this is the same coil, just different revision. Replaced coil and started car with durametric hooked up and cyl 1 was again misfiring, so I increased RPM and the misfire went away. I dropped back to idle, and just when I was thinking things were good, the engine made a bad noise and died. Many fault codes: All injector valve cylinders below limit, Heating power 02S ahead of cat bank 1 & 2, and P1571 code 39 Immobilizer. Again I found that the new ignition coil on cyl 1 was blown.

I'm thinking that it is not an ignition coil problem. Has anyone had a similar experience?

Thanks for any help,

Bill

The latest coil pack for your car is: 997.602.107.00

What are all the current fault codes?

Loren - Do you think the cause of the second blown coil is because I replaced the original with the wrong model?

[Loren]

I just brought my 2000, 911 out of storage and ran great until it developed a definite misfire. Fault code 63 - "Cyl 1 misfire damaging to cat". Upon inspection, I found the coil to be blown out (melted plastic) on the connection side of the coil. I bought a new coil and the part number was 996 602 101 01 instead of the original 996 602 102 00, but was told this is the same coil, just different revision. Replaced coil and started car with durametric hooked up and cyl 1 was again misfiring, so I increased RPM and the misfire went away. I dropped back to idle, and just when I was thinking things were good, the engine made a bad noise and died. Many fault codes: All injector valve cylinders below limit, Heating power 02S ahead of cat bank 1 & 2, and P1571 code 39 Immobilizer. Again I found that the new ignition coil on cyl 1 was blown.

I'm thinking that it is not an ignition coil problem. Has anyone had a similar experience?

Thanks for any help,

Bill

The latest coil pack for your car is: 997.602.107.00

What are all the current fault codes?

Loren - Do you think the cause of the second blown coil is because I replaced the original with the wrong model?

No, the old ones worked pretty much as well as the new ones - there should be no issues mixing them.

Look for a bad plug or a bad electrical connection on the coil connecting boot.

[wvicary]

Just another thought as you mentioned bringing it out of storage... maybe inspect the wiring for rodent damage causing a ground path and excessive current draw.

[brimwin]

Fault codes are:

1. 
   

153

62

63

66

150

152

155

151

154

13

5

14

4

39

How does the wiring connector to the coils look? Melted, usually the fuse for dme or ignition blows, check your fuses. Does car start up at least? If you do have a blown fuse, you may have either a wiring issue or bad Dme caused by shorted coil taking out one or more drivers. :huh:

vizcarra44 - Will the DME give me a fault code if there is an internal bad driver? I have inspected wiring to the DME and coil pack, and all looks good. I replaced the blown 30A fuse for the ignition, and all fault codes are clear! The plugs were replaced inbetween the first blown coil and the second. I suspect the DME was damaged by the first blown coil which then caused the second coil failure? Should I look for a new DME, or is there anything else I can test before going that route?

[kristian]

Usually when the part number changes but the product is the same, the manufacturer of the product changed. I know that Beru has used at least to different manufacturers to produce these coils. It should not make a difference in performance. I see these same coils beginning with 996 and 997 serial numbers on different websites.

Kristian

I just brought my 2000, 911 out of storage and ran great until it developed a definite misfire. Fault code 63 - "Cyl 1 misfire damaging to cat". Upon inspection, I found the coil to be blown out (melted plastic) on the connection side of the coil. I bought a new coil and the part number was 996 602 101 01 instead of the original 996 602 102 00, but was told this is the same coil, just different revision. Replaced coil and started car with durametric hooked up and cyl 1 was again misfiring, so I increased RPM and the misfire went away. I dropped back to idle, and just when I was thinking things were good, the engine made a bad noise and died. Many fault codes: All injector valve cylinders below limit, Heating power 02S ahead of cat bank 1 & 2, and P1571 code 39 Immobilizer. Again I found that the new ignition coil on cyl 1 was blown.

I'm thinking that it is not an ignition coil problem. Has anyone had a similar experience?

Thanks for any help,

Bill

Edited April 18, 2009 by kristian

[brimwin]

Thank you all for your help, and in particular vizcarra44. I found the wire loom to be shorted out against the convertible top tension cable bracket. Evidently the GN/BL ignition firing control wire for #1 cyl (from the DME) rubbed against this bracket long enough to wear through the insulation. As soon as I pulled the wire loom out of this spot, I seen the damaged wire as shown. I'm not sure how this causes the coil to blow as I wouldn't think it would even fire if the voltage is going to ground before triggering the coil, but all is well now and no misfires! What a relief. :renntech:

I see now that the DME supplies a ground for firing the coil, so a short anywhere in that trigger wire would cause the coil to be constantly firing.

Edited April 20, 2009 by brimwin

[dr914jr]

Thats really great! You could have been searching for a long time before you happened across that little guy.

[Loren]

Very unusual - good troubleshooting!

[phillipj]

Excellent work! You are very fortunate you found that.. :clapping:

[Mother]

KUDOS nice effort.

[warrennorth]

hi there anyone had or heard of this problem car came in not running lots of fault codes and blown coil fuses put new fuse in and smoke came from coil pack plug cylinder 5 took coil out badly cracked and plug is all melted problem i have now is porsche dont list terminals or plug or gasket to repair the loom they do for 996 and boxster but are different sorry i forgot this is a 2003 cayenne s

[Loren]

hi there anyone had or heard of this problem car came in not running lots of fault codes and blown coil fuses put new fuse in and smoke came from coil pack plug cylinder 5 took coil out badly cracked and plug is all melted problem i have now is porsche dont list terminals or plug or gasket to repair the loom they do for 996 and boxster but are different sorry i forgot this is a 2003 cayenne s

There have been several "revisions" to the coil packs used on the Cayenne's (there is a Technical Service Bulletin on this). I suggest changing them all to the latest revision.

[xmac]

Great troubleshooting considering the possibilities! I had something eat completely through one of my knock sensor cables that I had to solder back together. With your car, nothing a little friction tape and spiral wrap can't fix.

Edited November 10, 2011 by xmac