Closed spark plug - what can cause this

Beesza

Member
 Derbyshire
Took my coupe for its MOT last Wednesday. Drove in fine and dropped it off. Tester called at lunchtime saying the car was misfiring and shaking a lot. It was fine when I drove in so didn’t know what to make of this guy. Anyway, he was dead right. When I picked the car up it was shaking like a washing machine. It failed the MOT because they couldn’t do the emissions due to the misfiring and there was play in the Nearside Front Lower suspension arm ball joint. Not to fussed about the joint because I can easily replace that. The misfire on the other hand is far more worrying.

The garage i had taken it to was only a tyres and exhaust kind of place so they won't touch the engine. I drove it home gently and the EML came on which I was glad of as it give direction to the fault.

Got home, scanner out, cylinder 6 misfire code. I pulled all of the spark plugs and the cylinder 6 plug was closed which explains the misfire. Photo below.

Is it normal for old plugs to close? I assume that as plugs wear, the gap increases causing a misfire. Can the undetonated fuel collect in the cyclinder and eventually cause a mega bang and weld the plug together? The contraction of the weld causing the parts of the plug to pull together.

I'm wondering whether old plugs could make too much of a bang and weld themselves together? Or is this more likely to be something mechanical and contacting the plug? Loose piston. Broken piston ring. Worn out crank shaft bearing?

I gapped the plug and put it back in, switching it with the one in cylinder 5. Seems to run fine again. I've not had a chance to pull the plugs again before we went on holiday. Was going to see whether the plug now in cylinder 6 also got ‘squashed’. I'll replace all of the plugs very soon but need to diagnose the fault first.

Has anyone else had this? Any advise will be much appreciated.
 

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Looks like a small metal piece of debris has welded itself to the plug electrodes shorting it out, hence the misfire. Now you have to ask yourself how did a small metal fragment find its way into the cylinder. I would pull the Disa valve out and inspect it for damage, some models had a problem with the Disa flap falling apart and parts entering the engine. not sure which modelsthis happened on. If the flap hinge pin is metal it could be whats left of the pin if indeed it is a failed Disa valve flap collapse.
 
Or an alternative theory - the garage pulled the plug out, bent the electrode and refitted it resulting in a bad misfire. They then say the cars got a huge engine problem but we’ll do you a favour and take it off your hands for £2k less than it’s worth as it needs a new engine.
Maybe I’m just beyond trusting any garage these days 🤣
 
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