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[Greenbay packer]

I have various dis pack related questions and would much appreciate any help and advice people are able to give.

My 2.5 V6 has recently started to run really roughly, like its not firing on all cylinders.  This began not long after I found loads of rainwater sitting around all the plug leads after the car had been left on a slope. As this has happened before I thought it would be ok after drying and running but its still running badly so today I started to have a closer look at things.  I removed the easy to get to leads from the plugs on the drivers side and used an inline HT tester to check whether power was getting to the plugs - this showed the centre and rear plugs were receiving high tension spark potential, but the front one, no.1, wasn't. I took this front plug out and it was oily (or wet, though it seemed more oily), cleaned it, dried it, refitted it and tried again but the tester still wasn't flashing so no HT potential.  I took the plug out and tested it on another vehicle and it was working fine, so I refitted it to the V6, tried the tester again and still no power.  I haven't had a chance to look at the other side yet, but so far is it reasonable to conclude that the fault must lie with either the HT lead or Dis pack?

I've just looked at the Dis pack renewal guide in the maintenance section on here, which seems to show the same version of the pack as is fitted to my car so I assume the vehicle used for that is a 2.5 or 3.0 V6 http://www.omegaowners.com/forum/index.php?topic=109316.0, and I can see that it will be an absolute joy to replace!  From what I can find out there seems to be three units inside the pack, each of which supply two cylinders - would I be right to think that if one of these units fails the supply to both cylinders will be affected, so if I find another cylinder not working on the passenger side the fault can only be with the dis pack and not the HT lead.  If correct, looking at the diagram on the maintenance guide would I be right to assume that the centre, no. 4, cylinder is the one most likely to be not sparking? 

I've removed the windscreen scuttle and had a nose down towards the dis pack but was horrified to find I could only see part of one of the four bolts that secure it (I assume all 4 bolt holes are used, not just the two on the bulkhead side which will be easiest to get at) - I can't even get my hand in and feel the others!    I was amazed that I could actually see and read a Bosch part number on one corner of the pack though some small consolation.  When I refit a replacement unit, assuming this one is knackered, will just a couple of bolts be adequate to secure it?  Also, I've seen people on here and another forum mention relocating their replacement dis pack, but is this possible without cutting into the wiring loom and will it require a set of longer HT leads?

Two final questions, for now at least. Firstly, my lovely Haynes manual and some of the posts on here indicate that the dis pack can be replaced after just removing the scuttle and wiper motor, but the maintenance guide say's to remove the scuttle and plenum - which is the easiest/ best method please.  As I've yet to remove a plenum I'm a bit dubious of touching that.  Secondly, its obviously not ideal, but how harmful is it to drive the car on 4 or 5 cylinders if I have to use it before I can get the job done - I'm thinking mainly about unburnt fuel getting to the cats, etc, but there may be other issues too.

May thanks for any help given.

[Doctor Gollum]

Leave the scuttle and remove the plenum and inlet manifold. You will then be able to get both hands and a foot onto the dis pack.

Remove, throw in the bin and fit the new one

[Lincs Robert]

I removed the scuttle & wiper assembly.

Either way you will get back-ache afterwards!

[Lizzie Zoom]

When I did mine, as in the Guide quoted, it was on a 3.0.

I did not remove the wiper motor, but certainly the wipers and scuttle need to be lifted out of the way  If you take it steady it is all very doable, but expect scratched hands, arms, and a bad back!  The four bolts on the dis pack can be a sod as you are working blind.  But take it easy and you will soon have the new one in place. A complete new unit is the only way to go

Ignore the Haynes manual, and follow the guide.  Do not attempt to use the car whilst only running on 4/5 cylinders.  You will kill the cats and put strain on the engine.

[terry paget]

I have changed several, removing wiper arms and scuttle. You can see the rear fixing bolts, the front ones you can feel. You need a slim socket and extension to access and remove them. You may break one or two off, not to worry, three will hold it all right. I removed leads first, then bolts, then raised the pack and unplugged the plug.

Not too bad a job, but be prepared for several hand grazes and a stiff back.

[Lincs Robert]

Just for the avoidance of doubt - you will end up with back ache! 

[cam.in.head]

and then once you have checked / replaced all the plugs and know they are fine its time to check or replace the leads. if there is any doubt or they are originals or have been on for years then best to replace but if not they can be tested.assuming they do not feel crunchy and brittle on the part of the rubber boot above the plug(the heat realy gets them there)you can test them with a meter. on a 20k range expect a continuity of approx 16k on the longer ones coming down to a lesser / around 9k on the short ones.the leads are resistive hence the longer ones being higher.no reading on a 20k scale indicates a break or bad connection .and yes the coil is a bugger to get out but worth looking at.they can crack and cause ht leaks to earth.any cracks should be obvious .if you replace ive been told best to replace with a genuine bosch .cannot comment of pattern items .

[Lincs Robert]

One advantage of taking the scuttle/wipers off is that you can test it without putting those parts back on. 

[Greenbay packer]

Thanks for all of the replies - looks like I've got some back ache to look forward to then!  Think I'll leave the plenum for now and try with wipers and scuttle removed as I like the idea of being able to run the engine and test the replacement and the leads before putting everything back together.  Thanks again 

[TheBoy]

Thanks for all of the replies - looks like I've got some back ache to look forward to then!  Think I'll leave the plenum for now and try with wipers and scuttle removed as I like the idea of being able to run the engine and test the replacement and the leads before putting everything back together.  Thanks again 

Brave.

I wouldn't.

[Lizzie Zoom]

Thanks for all of the replies - looks like I've got some back ache to look forward to then!  Think I'll leave the plenum for now and try with wipers and scuttle removed as I like the idea of being able to run the engine and test the replacement and the leads before putting everything back together.  Thanks again 

Brave.

I wouldn't.

.................yes, because without the plenum removed the task cannot be done...........that is what I have experienced anyway!

[Migv6 le Frog Fan]

It can be done, but its not worth the hassle - from memory.

[Nick W]

It can be done, but its not worth the hassle - from memory.

That was my experience too.

[Greenbay packer]

Thanks for all of the replies - looks like I've got some back ache to look forward to then!  Think I'll leave the plenum for now and try with wipers and scuttle removed as I like the idea of being able to run the engine and test the replacement and the leads before putting everything back together.  Thanks again 

Brave.

I wouldn't.

Ok, guess I was just being ultra hopeful and thinking 'there's only four bolts, how hard can it be?' - very by the sound of it! Not had the plenum off before so am a bit wary but if it has to come off I'm hoping its one of those jobs that once its done I'll be wondering what I was fussing about. I'm still half hoping it might just be an HT lead as I seem to have a spark at 5 out of 6 but nothing at the front right, but that is probably wishful thinking.  Thanks again.

[cam.in.head]

can you manage to remove the offending lead or for that matter all the leads with plenum still on. i did it a few weeks back but with it removed. cant recall if you can.lets say you can. and you have access to a meter it might be worth checking the leads first. water and heat does seem to kill them.