Don, I'm pretty sure this problem is related to a grounding issue with one
of the coil packs and not the coil itself. It just happens to act up every
time I remove one of the bolts and it doesn't get torqued exactly the same
way that it was.
Last night, I took the car over to my fathers garage and brought the old AC
Delco coils with me. I know for a fact that the very first time I changed
the coils that they were bad, because the plastic was cracked and allowing
moisture into two of the coil packs. The third did not have any cracks, but
I changed it out anyway because the car has such high mileage (nearly
300,000kms). At that point, I took it to a local garage that scanned the
computer and read that 4 out of 6 cylinders were randomly misfiring. When
it started misfiring again the other day, I wasn't absolutely sure that it
was the coils that were "bad" or "worn out", but the symptoms were nearly
identical to the first time it happened when it was scanned with an OBD-II
scanner.
Thinking I may find a fouled spark plug, I pulled all three of the spark
plugs on the front of the engine. The center plug was obviously misfiring
because I could smell the unburned fuel on the electrode. The other two
plugs were fine, so I traced that single spark plug wire back to the coil
and decided to switch it out with one of the used AC Delco coils. While I
was bolting the AC Delco coil back on, I noticed that the front bolt was not
tightening very well. I pulled it back out and discovered that the threaded
hole was stripped on the mounting plate. The back bolt was ok, so I
tightened it with a nut driver as tight as I could, and then managed to
tighten the front bolt fairly tight by hand.
Now, from what I can tell, the coil uses both bolts to ground itself to the
distributor plate and I think what is happening is the coil is loosening
over time because of that stripped hole and it is losing ground, causing the
coil to misfire. Again, when I started the car and put it in gear to load
test it, the engine ran fine with no hesitation. The engine light was still
on, but not flashing. So today, I think I will go back over and find a nut
to fit the bolt and if it's at all possible, try to fasten the nut on the
underside of the distributor plate I don't know if there is enough metal
left to tap the hole, but I may try that first.
Thanks for the suggestions,
Sharky
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