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Subject intermittent 5 cylinder running cured(coil pack #4 bad)...
     
Posted by earthpunk on November 25, 2013 at 3:41 AM
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Message My '93 TT started running on 5 cylinders sometimes; often when started cold. A lot of times the rough running would only last a few seconds and then the missing cylinder would start working, but sometimes rough running would last minutes. Listening closely to the 2 exhaust pipes in turn when running rough revealed that the problem was with the driver's side cylinder bank (I could hear that the driver's side exhaust pipe sounded rough compared to the passenger side). One day the engine ran rough all the way to the grocery store (yes, I realize it's not nice to run the engine that way), and I was able to feel the driver's side upper plenum by hand and tell that that #4 intake air runner was warm, but #2 and #6 were hot, so the problem was with #4 (the middle one). This spared me from having to figure out how to do a 'load test' with conZult freeware, if even possible. I had previously changed the injectors and plugs myself and had confidence in my and NGK's work, so I replaced the #4 coil pack with a brand new one and the problem did go away. I later found a '93 NA at the junkyard and snagged its coil packs except for #4 due to visible bubbling on the surface (heat damage, I thought) at one part of the coil pack. Hmmm... Based on these 2 data points I wonder if #4 has the worst thermal environment. I note that the the front and rear cylinders have (hot) neighboring cylinders on one side only, but middle cylinders have (hot) neighboring cylinders on two sides, which might contribute to a harsh thermal environment for the middle cylinders. The passenger's side seems more open to the air for cooling than the driver's side, too. Just speculating... :?) After 1000 miles with no rough running, I replaced the nearly-new coil pack with one from the junkyard, so I could keep my nearly-new spare in nearly-new condition. I've driven thousands of miles since then with no rough running. Zee-yeah!

     
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