1.2TSi ignition pack failure - anyone else?

[Jhouse_101]

mine went on friday, but on my 1.4tsi cupra...

 

[znww5]

Sorry to hear that, but interesting to see that yours is a MY2011 vehicle as well.

 

[AsturRS]

AsturRS - you write better English than many people who know no other language - welcome to the forum!

Glad to hear that. Thank you

BERU - is a division of Borg-Warner ( the automatic transmission people ) and is based in Germany. The company seems to specialise in ignition components such as ignition packs and coil-on-plug assemblies.


There are three things which caught my attention regarding the ignition pack failures:

i) it always seems to involve the HT leads
ii) the HT leads seem to have a track record of failing and
iii) production year 2011 may be a common factor.

Because it's the weakest point of the ignition system.

Although I find it difficult to believe that somebody would design an ignition pack which had inadequate short-circuit or open-circuit protection for the HT side, the involvement of the HT leads would suggest that is the case. My HT leads (including the two new ones) have no manufacturers markings at all - and it is interesting that AsturRS has had multiple failures of his OEM leads too, but the replacements seem to be OK.

So, is it simply a case of a faulty batch of HT leads being fitted in late 2010 / early 2011 which caused the ignition pack to fail? Or was it a case of faulty leads and a poorly designed ingnition pack?

I believe the HT leads are not the problem, as i said i think they are a sympton. If the involvement of the lead is poorly made and/or is too thin, the engine will misfire sometimes (particulary on heavy use) instead of a sudden failure with a total loss of the cable, because part of the electricity will escape from the conductor, resulting in a poor spark.

I believe the problem is overvoltage. It's the only way a conductutor can crack because a electrical related problem in a really low current system as far as i know.

BTW, when i had the first problem i'd double checked everything before calling for a tow truck, and found a lot of white deposits on the inside of the #3 cylinder insulator of the coilpack, the rest of the insulators where ok with some yellow/black deposits. On Monday i checked the #3 insulator again (i cleaned it when i had the first problem) and it shows a lot of brown deposits.

PS Does anybody know if there has been a change to the part number for the ignition pack, suggesting a re-design?

I don't know, the other 1.2TSi engines that i know are MY12 and they still have a low mileage.

mine went on friday, but on my 1.4tsi cupra...

Sorry to hear that. The 1.4 TSI uses coil-on-plug instead of a traditional DIS system (Coilpack - HT Lead - Plug) like the 1.2. Can't be the same problem.

PS: The dealer called my today, the car is fixed again, they just changed HT Leads #1 and #4. Same fix of the last time.

 

[Jarre]

Just thought I'd update on mine since I never did - I had a leaking injector. It was replaced under warranty by the 3rd dealership it went into!

 

[Webstuff72]

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