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Discussion Starter · #1 ·
2014 LTZ 1.4L Turbo ~ 60k miles.

My original factory OEM coil pack failed around 55k miles. Two of the ports were deeply corroded. I replaced it with an aftermarket coil, and the car ran fine for about 2 months. Then one day on the highway the engine cut out and it would not start. After about 10 minutes of waiting for the tow truck, I tried it again and it started up and ran fine for a few more days. The problem started occurring more frequently until the car became undrivable. I called the company and they sent me a replacement aftermarket coil. With the "new" replacement the car would not start at all. If I put the old aftermarket in, it would start right up and run for a few minutes. I complained and the company sent me another replacement. With this third aftermarket replacement, the car started and would run forever, but the engine was skipping. (ECU 420, Traction Control, etc.). I replaced all the plugs, but the problems never went away. I moved plugs around and the skip stayed with Cyl #1, which led me to believe the coil was bad. I did a compression test and cyl #1 had good compression. I decided to buy an MSD coil and stop messing around. While waiting for the MSD to arrive, I rebuilt my original OEM coil the best I could. I cleaned out the rust on two ports and put on new boots, etc. The car started fine and ran perfectly for about 20 minutes. As soon as it heated up, it would start skipping with the old OEM coil. The next morning it ran fine again until it heated up. Finally the MSD arrived. Installed the MSD, and the car ran perfectly for 10 minutes and died. The car would not start again. I pulled the MSD out, and put in my original OEM coil and got the car home.

What is causing all these problems with the coil packs? Is there something else that I'm missing? I refuse the believe a new MSD is bad. I've inspected the connector to the coil and it's in decent shape. What else could be causing this? I've cycled about 6 coils in and out, and can seem to get a good one? Each coil pack consistently fails in it's own unique way. Pack 1 skips, pack 2 randomly dies, pack 3 won't start, pack 4 skips, pack 5 died, etc. Out of desperation I even replaced teh original battery, which was 5 years old, but it had no impact on the problem. My only guess is the voltage going to the coil is too high or low, or the digital signal or timing is messed up.

Any ideas?
 

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Discussion Starter · #5 ·
I like Robby's theory, but I'll add another thing to check - spark gap. The bigger the gap, the more stress it puts on the coil as it takes a higher voltage to jump it.
Thanks everyone for your suggestions.

  • Yes the coils came with brand new boots
  • I'll give the wires another good inspection to see if I can find any wear points
  • plug gap - great idea, I did make sure they were gapped to .30
  • Camshaft sensors - will check.
 
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