Pug problem - FIXED with angle grinder

[werner]

O K, not only the angle grinder, but insulation tape ( temporarily )

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With renewed hope I started to battle with the pug again today.
Removed the coil pack and plugs to do a compression test.
No 1 and 3 was a bit lower but after making sure the tool was tightened all the way they were 1250 kP as well

[werner]

Removing the coil packs is a bit of a problem as the right hand drive conversion has the brake master cylinder on top of the coil pack and it needs some work to get it out and even more work to get it back.
The result is that at some stage the boot cover that goes over no 1 and 2 starts to tear. When I removed it today, I found this white spots on no 1 and 2 cover and this is where it is losing spark while idling.
I fixed it for the moment with insulation tape and seeing that the allen bolt in that corner underneath the brake cylinder is long gone, I sommer used an angle grinder to cut the corner away. First cut , tried and then some more, fit.
Now the "pug" is purring like a "cat" again.

I do not know how long the insulation tape will last, as it is getting hot in there. Will get replacement boots as soon as possible.

In the last pic the copper plumbing is a home made bypass for the plastic heater that was cracked after the mechanic has changed the damper pulley and timing belt

[ters]

Now the "pug" is purring like a "cat" again.

Happy times!

Ters.

[IndianaJones]

Glad you found the problem.
Was the cracks not clear when you changed the sparkplugs before?

It's a pity all the websites state coil pack failure to be a known problem, but not exactly how it fails, could be the cracks is the reason it fails.

[werner]

That boot is a very soft rubber and it fits into a "pipe" ( no better description). The spark plug also slide in there and it is quite deep. Fitting the coilpack, one has to bend the boots of 1 and 2 and push the coilpack in at an angle. There is no way to see if it is going in right and only a resistance tells you it is not in. The cracks is actually tears from having it not completely in the pipe. I never thought it was that close to being earthed and the spark jumping through. The white marks only showed yesterday for the first time. According to the peugeot service box the extentions do come lose.

I just wonder how many expensive coil packs have been changed on right hand drive vehicles while it was only the boot - extention that was the problem. It was never mentioned on any forum discussion that I had seen

[werner]

Just some feedback.

The agents is charging R1000.00 for a set of extensions, only available in complete set. Then I had to wait six weeks for delivery. I tried a few local places, but the best reaction was a dumbed face. In the mean while the pug just keeps on running.

It is now three months later, used every day and two trips to Darling (just over 100 km there and a 100 back again ) at 140 kph on N7 and the insulation tape is still there. The condition of the insulation tape ? , I do not know. I'm actually scared it do'nt want to come out if I try to remove the coil pack again.

If the pug is happy, just leave it.
Just got to fix the exhaust, but that can wait as well.

[werner]

After more than 15 months I had enough courage to remove the coil pack again to check the spark plugs.
The pug was still running fine, but I was just curious. I did not know what to expect.

Out she come and.......

Just a little bit of discolouring of the tape.

I wonder how many thousands of extentions and coil packs has been changed at huge cost just because the right hand drive version had the brake master cylinder over the coil pack and the rubber was getting cut by the sharp edge when replaced.

[paulusvrotius1]

Some heat shrink sleeving would make a more permanent repair Werner.

[Johann66]

Reminds me of my 58 Peugeot 403 with those long bakelite connectors! If they crack your car willmissfire!!