OBD errors: p0201-06 / melted ignition coil / car doesn't start

[d0lph1n]

1. Engine stopped and it doesn't start.

2. OBD codes: p0201 to p0206

Cracked coolant resevoir licked coolant all over the left side of the engine:

- one of the ignition coil has melted plastic around contacts (smells very bad too)

- the ignition coil plug socked is also melted

I've tried to restart the engine with this coil disconnected (a desperate move). It refused to start and it drained the battery extremely fast (i'm an idiot, have mercy, please).

Please let me know:

1. where to find/buy a new ignition coil plug socket? (I found them in Australia)

2. After i install a new coolant tank, a new ignition coil and a new plug socket what else should i look for before attemting to start the car?

3. Why so many error codes (p0201-2-3-4-5-6) if only one ignition plug was affected? What have I done?!

Thank you very much. I apprecite it.

Edited January 25, 2015 by d0lph1n

[RFM]

If there is a coil which melt by an internal short-circuit, the fuses of the INJECTION system may blown as a protection of the catalyst. That works that way on most of the Bosch products, you should defenitely inspect that before costs are incurred.

[d0lph1n]

I appreciate it. Do you know where is this fuse located?

[Loren]

I appreciate it. Do you know where is this fuse located?

 

D7 a 25A fuse.

[d0lph1n]

The D7 fuse looks ok. Anything else? Thanks

Edited January 25, 2015 by d0lph1n

[Loren]

Did you check it with an ohm meter out of the circuit?

 

Those two codes are pretty specific to no injector power.

[d0lph1n]

No, i just checked it by removing it and inspecting it. I'll check it with a meter.

Any idea where i can find the the ignition plug socket (green arrow)

 

pic02.jpg

Edited January 26, 2015 by d0lph1n

[d0lph1n]

According to my research my car has the ME 7.8 and the fuses & relays for the motronic section can be found in the following positions:

 

Fuse carrier in left footwell: B1, D1,D4,D6, D7

Fuse carrier in rear: F1 (fuse potion 6 on relay carrier 2)

Relay Carrier 1 in left footwell: Fuse 8,12,14,16

Relay carrier 2: Fuse 8,9

 

Please confirm.

[Mijostyn]

dOph1n, That is the male connector on the ignition coil wire. Replacing just that requires a special tool to remove the individual pins which are locked into the housing of the plug. I suspect you probably have to buy the whole wire as an assembly. JFP or Loren can correct me if I am wrong on that one.

 

The Rubber boot must have been off that plug and coolant got into it. It should have been protected by a fuse and not melted like that. Make sure the ignition fuses are all the right value. Someone may have stuck a higher value in there. If that fuse is not blown, replace it as it may be defective.

Edited January 27, 2015 by Mijostyn

[d0lph1n]

All the fuses I checked so far have the correct value. In my previous post, the porsche doc specifies a lot more fuses and relays than the car's manual. Also a Porsche mechanic from Germany, the neighbor of a good friend of mine, advise me to look for those extra relays and fuses, especially in the back. He couldn't say exactly where to look for without seeing the car. He also said to replace the entire cable.

Buying the whole wire is not the problem, installing it is. Do you know where i can find the special tool?

Edited January 27, 2015 by d0lph1n

[Loren]

Both SirTools and  PlusQuip (or Steelman)  sell compatible tools.

 

SirTools

 

PlusQuip or Steelman

[d0lph1n]

Thank you Loren. I appreciate it.

 

I found this on Amazon, very similar if not identical to the PlusQuip:

Wilmar (w89732)

 

and also something similar on ebay:

Powerbuilt (641448)

[d0lph1n]

To install the new socket, do I need a crimping tool?

[Ahsai]

If the old pins and wires are in good shape and you can reuse them, you just need to remove and transfer the individual pins to the new connector housing so no crimping tools are needed. You need the crimping tools only if you need to replace the pins in which case you most likely will need to cut the original wires and add more wires to make it same length as original.

 

An example of cayenne connector http://www.suncoastparts.com/product/955V8PLUG.html

Another example for 997 here http://www.ebay.com/itm/1x-New-Connector-Set-For-Porsche-911-996T-GT2-GT3-997-Carrera-Ignition-Coil-/171077008052

 

Check with your local dealer and they should be able to sell the connector to you or give you the p/n.

 

If you remove the old housing, you may fine very small part numbers printed on it and it's usually manufactured by TE/AMP/Tyco.

Edited January 27, 2015 by Ahsai

[d0lph1n]

Ahsai, i appreciate your reply.

 

The old pins might be compromised but I'm trying to preserve the length and the integrity of the original wire.

 

The dealer asked for more info (the exact picture or part number), I'm still waiting for a reply.

Meantime, I ordered 3 sockets  from the ebay seller (australia) and the toolset recommended by Loren.

The car battery is in the charger.

 

Before I attempt to start the car again, I'm planning to:

- replace the coolant expansion tank

- replace all the ignition coils & spark plugs (arriving today)

- identify and check all the fuses & relays for ME 7.8

- replace the damaged ignition male socket

- if I can find/borrow/buy a durametric tool to check for more error codes

 

Anything else?

Edited January 27, 2015 by d0lph1n

[Ahsai]

Sounds like a good plan.

 

BTW, just corrected the 1st link in my previous post http://www.suncoastparts.com/product/955V8PLUG.html

[d0lph1n]

The terminal removal tool kit has arrived. I'll try to remove the plug today. The new plug will arrive soon.

Meantime, check out the old melted plug below.

Edited January 28, 2015 by d0lph1n

[Ahsai]

Yikes! Looks unlikely you can remove the pins without destroying them in the process.

[d0lph1n]

Update:

 

1. The ebay connectors from Australia have been on hold at LAX since the 1st. USPS sucks.

2. I contacted more than 5 stores, not including Pelican parts and 2 Porsche dealerships. Only one store was able to give me an alternative.

3. I was able to find the exact cable terminal (just the cable housing) in the Bosch catalog // Bosch part number 1 928 403 110. I purchase it from http://www.nexelec.com (the product photo is wrong). I've also purchased Bosch 1 928 403 970 but it doesn't fit properly.

4. The new ignition coils are ready to be installed. The new Bosch connector fits perfectly. I'll try to reuse the existing pins if not I'll probably replace them with something similar made by Tyco.

5. Tool 21 from Wilmar (W89732) 23-Piece Terminal Release Kit looks like it will help me remove the cable from the old port.

 

Additional photos of the existing OEM part (used but in good condition). I was able to identify the following codes:

192840 (also found on the new Bosch connector 1 928 403 110)

PA 66 GF 30 (also found on the new Bosch connector 1 928 403 110)

21

321 (cable numbers also found on the new Bosch connector 1 928 403 110)

.2868 (after removal)

 

The correct part number is : 1 928 402 868

Edited February 10, 2015 by d0lph1n

[d0lph1n]

If the old pins and wires are in good shape and you can reuse them, you just need to remove and transfer the individual pins to the new connector housing so no crimping tools are needed. You need the crimping tools only if you need to replace the pins in which case you most likely will need to cut the original wires and add more wires to make it same length as original.

An example of cayenne connector http://www.suncoastparts.com/product/955V8PLUG.html

Another example for 997 here http://www.ebay.com/itm/1x-New-Connector-Set-For-Porsche-911-996T-GT2-GT3-997-Carrera-Ignition-Coil-/171077008052

Check with your local dealer and they should be able to sell the connector to you or give you the p/n.

If you remove the old housing, you may fine very small part numbers printed on it and it's usually manufactured by TE/AMP/Tyco.

The ebay connector(s) , from Australia, arrived today and I can confirm it doesn't fit, neither the housing nor the pins/terminals. A completly waste of time ...and money. don't get this one: http://www.ebay.com/itm/1x-New-Connector-Set-For-Porsche-911-996T-GT2-GT3-997-Carrera-Ignition-Coil-/171077008052

The Bosch connectors mentioned in my last post fit perfectly. I was able to reuse the existing pins and the silicon gaskets. None of them was damaged before or during the procedure. I change all 3 plugs from the left side using the terminal tool. I strugled ony with a center pin for a while. Below I will attach 3 photos with the oem vs part i found

The complete oem part number is: 1 928 402 868. You can find it on ebay, the complete kit, housing-pins-silicons - for $9 http://www.ebay.com/itm/Bosch-1-928-402-868-3-Way-Connector-Kit-/110458797063

The part number of the connector I found in the Bosch catalog is 1 928 403 110, housing only.

Edited February 10, 2015 by d0lph1n

[Ahsai]

Sorry the Australian plug doesn't work and hope you can get some refund.

Good job repairing the connector. How did you find the right part number? Is it printed on the old connector?

Edited February 10, 2015 by Ahsai

[d0lph1n]

Sorry the Australian plug doesn't work and hope you can get some refund.

Good job repairing the connector. How did you find the right part number? Is it printed on the old connector?

 

 

It's not your fault. I found that seller before you suggested it. Thanks anyway.

 

The old part number (bcz it's a long number) is split in 2 ...and placed on the connector in 2 dif. places. By looking in the Bosch catalogue...I got familiar with their codes...and I've been able to identify the correct oem number...but only after removal. I couldn't see it in the first set of photos (nor I didn't know where to look for).

 

Last night, I ordered 6 oem connector kits from ebay..just in case. As far as I understand from the german Porsche mechanic, this is a common problem, most of them being replaced under warranty. So maybe it's a good idea to have some new connectors around, just in case.

 

I'll let you guys know if this is the correct part...but I've very confident it is.

 

PS: If I think about it, the newer connect (1 928 403 110) has less open space (between pins), it doesn't have the vertical open space (perpendicular on the ignition coil pins) where water &/or coolant might slip in, it's hard to explain it without a proper photo. I'll try some macro shots.

Edited February 10, 2015 by d0lph1n

[d0lph1n]

Yikes! Looks unlikely you can remove the pins without destroying them in the process.

 

Sir, you were wrong (not by much).

 

Only 1 pin was very stubborn..I had to dissect the connector, slowly and carefully, piece by piece. It took me probably 1h and some luck.

Edited February 10, 2015 by d0lph1n

[Ahsai]

Ok, this will be the case I'm glad that I'm wrong :)

[d0lph1n]

After a few long hours of instaling the coolant tank (lowering the freaking engine etc.) and another hour of putting everything back* and checkingall the fuses again, I attemped to start the car. With the battery fully charged, the engine started right away but it stopped after just a few seconds and a bunch of errors and warnings pop-up on the console and later, on the obd2 reader. Well, in that moment, I was very tired...and extremely scared.

After clearing the errors, I drove the car but still, same errors and warnings. The engine was running smootly but it had a weird behaviour during acceleration. *Then I realized i forgot to connect the air flow sensor. With everything finally connected, i cleared the errors one more time and all the warnings vanished.

Now the car drives better, stronger, faster and smoother (it keeped up with a tesla on pch). I can't go to sleep, i have to drive it again...and again. Too bad I had too many stellas since i finally finished testing it. Otherwise anytime is good time to drive your favorite car, especially when the streets are empty, isn't it?!

Love is a strong word, but i really enjoy driving it, especially now. It's probably a very subjective opinion: it took me 3 weeks to fix it, without a proper garage, in front of my apartment, in full sun and with all the neighbors making "funny" remarks (There were few moments when killing was totally justifiable).

So..I thank everybody, who replied to my post, thank you very much for your help. I appreciate it.

Edited February 15, 2015 by d0lph1n