[Brett]

What the hell can make a coil and plug start to melt at the out side of the plug? Wires are good and the rest of the Collins is fine. It's the rear d/s coil

[atari4x4]

coil spring?

coil pack?

what car?

deeeetails FFS

[Brett]

Coil pack, 95 v6 h20a

Never knew coil springs had plugs or wires in them....

[atari4x4]

coil springs with wires

[droverdave]

You're so cleaver atari.

Melted coil indicates its shorting somewhere near, probably a crack in the coil in the plastic somewhere.

Pics would be good to help further.

[atari4x4]

EAD some minor details would help

Brett wrote:

Coil pack, 95 v6 h20a

Never knew coil springs had plugs or wires in them....

what part has melted, the coil pack or the probe?

my guess is the springs & rod inside the probe are rusty & crusty & causing massive resistance.

[DAB]

Cooling Failure
The two circuits in the ignition coil also generate a lot of heat. The coil has oil flowing through it to keep the wires cool. If the oil becomes too dirty or fails, the build-up of heat can burn out the system.

Spark Plugs
Spark plugs also can burn out, especially if the spark igniters are separate for each plug. Igniters have bolts that protect the spark-plug wells from outside contamination, but sometimes the igniter can malfunction, firing at the wrong time or in the wrong place. With just a slight amount of difference, the spark plug fails. Spark plugs are not part of the ignition coil itself, but when people refer to the "ignition coil," they usually include the spark-plug igniters in the reference.

[DAB]

thats something a mate just pulled off the net, lol, hope its helpful

[Brett]

It's the plastic around the plug (wires to coil not spark plug) guess its a cooling oil problem has leaked. Ill pull it out tomorrow and put some pics up. Has me stumped as I was looking for a intermediate miss and found this and one broken (top of coil pack) coil. Don't want to put a new set in and fry it.

[DAB]

so your HT (high tension) lead had melted. ok... is it the rubber part on the end that goes
over the plug? if so has oil going onto it? the rubber will break down if soaked in out.
its in been missing on and off for a while then might be long time over dure for a new set of HT leads???

[atari4x4]

the coil packs & probes look like this DAB, there is no "high tension lead" as such & mentions it was the plug going into the coil & not the probe part.

[DAB]

lol.. thought it was 1.6 oops. have no idea where I got that thought from ... my bad

[fordem]

DAB wrote:

Cooling Failure
The two circuits in the ignition coil also generate a lot of heat. The coil has oil flowing through it to keep the wires cool. If the oil becomes too dirty or fails, the build-up of heat can burn out the system.

Spark Plugs
Spark plugs also can burn out, especially if the spark igniters are separate for each plug. Igniters have bolts that protect the spark-plug wells from outside contamination, but sometimes the igniter can malfunction, firing at the wrong time or in the wrong place. With just a slight amount of difference, the spark plug fails. Spark plugs are not part of the ignition coil itself, but when people refer to the "ignition coil," they usually include the spark-plug igniters in the reference.

DAB wrote:

thats something a mate just pulled off the net, lol, hope its helpful

DAB wrote:

lol.. thought it was 1.6 oops. have no idea where I got that thought from ... my bad

This is the problem with the internet - too many people regurgitating crap that they found elsewhere on the internet - and far too frequently, neither the person regurgitating the crap nor the person who wrote it have the slightest clue what they are talking about..

There are "oil filled" ignition coils - but the oil does not flow anywhere, does not get dirty or fail - and unless I'm very much mistaken the coil packs used on the 1.6 aren't oil filled - early 1.6 engines with the distributor did ship with oil filled coils, but if it's a coil pack equipped engine, then there's no oil there.

Also spark plugs will fail, whether or not the igniters are separate - in fact I've had more plug failures on engines equipped with breaker points (the original "igniter"), than I've had with electronic ignition, separate igniters or not and will someone please explain to me how the hell an igniter bolted to the firewall (for example an early SV418 or SV620) can protect the spark plug well from contamination.

Brett - melting around the harness connection to the coil pack can come from two sources - a high resistance connection which I think is unlikely - there's is not that much current flowing and it's not a continuous flow, unless an igniter fails (more on this below), or an internal failure of the coil pack - it is possible if the high voltage winding develops a short to generate extreme high energy arcs which can melt the plastic.

I have also seen (on a non Suzuki coil pack) an arc from the high tension side of an otherwise fully functional coil, flash over and burn through the plastic body (excess moisture in the plug wells is a contributing factor) - the reason I know the coil to be fully functional is I repaired the hole and have been using the coil for the past year or more.

There are two types of coil pack used with the H20A V6 - the first few years of SV series production had an igniter module on the firewall and "two wire" coils (two wire harness connections) later models had the igniter in the coil pack, these are "three wire" coils as there are three wires in the harness connection) - you can see the three connections in Atari's picture. If an igniter transistor short circuits it could conceivably draw enough current to overheat and burn the connections - a 95 should have two wire coil packs, so I would guess at an internal failure of the coil.

Edit

After further thought - a failed igniter module would probably overheat the connection on a two wire coil pack also - pay close attention to the harness connector as well - if that shows signs of overheating & burning that could be a problem.

[atari4x4]

fordem wrote:

This is the problem with the internet - too many people regurgitating crap that they found elsewhere on the internet - and far too frequently, neither the person regurgitating the crap nor the person who wrote it have the slightest clue what they are talking about...