Can't Pull Ignition Coils - SOLVED

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Lester
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Drives: 2008 Polo 9N3 1.4 BUD
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Can't Pull Ignition Coils - SOLVED

Post by Lester » Sun Jan 13, 2019 3:36 pm

Hi Everyone,

I want to remove my spark plugs to do a visual inspection and see if they need replacement. I don't have the service history of my car so I'm afraid my plugs are due for replacement. Pulling them with my bare hands don't work so I bought an ignition coil puller (T10094A).
puller (Copy).JPG
I thought I could easily get them out but they are still very difficult to remove. I tried hammering up the puller handle but I stopped because it doesn't seem to be a good idea. I tried twisting left and right. It moves a little from side to side but not upwards. I can't pry it up with a flat screwdriver because of the plastic wiring guide around the ignition coils.
coil (Copy).JPG
I'm thinking of devising a screw type puller that can sit on the camshaft housing. If anyone has any tips on removing an ignition coil, please let me know. Thank you.
Last edited by Lester on Mon Jan 21, 2019 1:21 am, edited 1 time in total.

RUM4MO
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Re: Can't Pull Ignition Coils

Post by RUM4MO » Sun Jan 13, 2019 5:07 pm

That puller should give you your best chance of pulling these coils up, I had removed all the coils on my wife's old Polo 1.4 16V before I bought a coil puller kit, and the method I used was to lever them up using 2 suitable screwdrivers, taking care not to damage the plastic cable management part. Only ever lever in close to the centre line of the spark plug to avoid snapping them off.

I'd think that if you try using 2 screwdrivers - one opposite the other to avoid damaging the coil, then applying steady pressure, these coils will come up enough for you to fit the puller back on and lift them out.

Lester
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Re: Can't Pull Ignition Coils

Post by Lester » Tue Jan 15, 2019 1:12 am

Hi RUM4MO,

Thank you for tip. I tried it but the screwdrivers have nothing to pry against except the plastic wiring guide.
I will make something that can sit on the camshaft housing and attach the coil puller. Will share it here later. :)

Lester
Getting There!
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Drives: 2008 Polo 9N3 1.4 BUD
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Re: Can't Pull Ignition Coils

Post by Lester » Mon Jan 21, 2019 1:20 am

I have finally removed the ignition coils by making this little hoist using metal bars and wood.
It sits on the camshaft housing and pulls the puller up as you tighten the nut. Works well. :D
igncoilpuller.JPG

RUM4MO
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Re: Can't Pull Ignition Coils - SOLVED

Post by RUM4MO » Mon Jan 21, 2019 11:38 am

That certainly should have solved your problem!

Now to re-engineer that coil puller back to having a Tee handle as I don't think that you will ever need that much effort to remove these coils in the future.

I'm guessing that it was only the rubber seal that was gripping so well and stopping you lifting these coils out?

Plugs come out okay?

Lester
Getting There!
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Joined: Wed May 02, 2018 4:59 am
Drives: 2008 Polo 9N3 1.4 BUD
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Re: Can't Pull Ignition Coils - SOLVED

Post by Lester » Mon Jan 21, 2019 2:20 pm

Hi RUM4MO,

Putting the tee handle back to the puller/fork is easy. I actually attached it back as I used it to firmly press the ignition coil back.
Ignition coils 2, 3 and 4 came out without issues but I had an issue with coil 1.
The metal part of the coil did not come out. It got stuck in the hole so the coil came out without it.
coilstuck.JPG
coil metal stuck in hole
coilnometl.JPG
coil without metal
Coil 1 still works when I reinserted it but my plan is to replace it after I receive the replacement coil I ordered. I will forcefully pull out that metal part with pliers.

I could only get 3 spark plugs. The spark plug wrench won't fit when the metal thing is there. Plugs are rusty so I think they have never been replaced since the car was bought in 2008.
I will replace all the spark plugs.
sparkplugs.JPG
rusty spark plugs

RUM4MO
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Re: Can't Pull Ignition Coils - SOLVED

Post by RUM4MO » Tue Jan 22, 2019 9:35 am

Oh, that is a bit annoying, it must be the sealing ribs of the rubber gasket that is gripping the sides of the counterbore in the aluminium alloy cylinder head - and the metal shield will just be gripping the inner bore of that rubber gasket.

I'd not think that that happens very often, in fact I've never ever read about that happening on any VW Group similar engines - replacing the plugs at the 4 or 6 year point in its life would probably have avoided that, also to make things worse, any engine oil spilt during servicing/maintaining would end up on top of that rubber gasket adding to its troubles.

Lester
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Re: Can't Pull Ignition Coils - SOLVED

Post by Lester » Wed Jan 23, 2019 1:12 am

Hi RUM4MO,

Yes, I was kind of sad that one of the ignition coils broke but that's ok. I ordered an original VW ignition coil (036 905 715 E) but it's not new. I think it's better to have 4 originals than to have 3 VW and 1 aftermarket brand.
I agree with you that it was the rubber gasket. The metal shield from the coil and metal from the spark plug well shouldn't be gripping that tight.
I never realized that spilt oil could make it difficult for the coils to come out but yes, it looks like some oil was spilt when refilling at one point. I'll have to clean that up.

RUM4MO
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Re: Can't Pull Ignition Coils - SOLVED

Post by RUM4MO » Wed Jan 23, 2019 3:20 pm

When I needed to replace any coils on my wife's old 2002 Polo 1.4, I always bought either "new old stock" or used but still okay Eldor coils which was what that car was fitted with at the factory.

In 13 years 105K miles I only needed to replace 2 coils.

Lester
Getting There!
Posts: 66
Joined: Wed May 02, 2018 4:59 am
Drives: 2008 Polo 9N3 1.4 BUD
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Re: Can't Pull Ignition Coils - SOLVED

Post by Lester » Wed Jan 23, 2019 3:53 pm

I am doing the second option you mentioned which is to buy a still-okey Eldor coil.
I am getting one that was taken from a 2007 Golf with 80K on its odometer. My Polo already has 99K.
Here's a photo of the Eldor coil taken from my 9N3.
coileldor.jpg
Eldor ignition coil

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