Burnt Plug wire - off to get my ENGINE VENTILATION COOLING KIT

[Paul T]

Sorry to start a new burnt spark plug thread on this old topic but it seems one cannot reply with a photo to those post over 250 days old. At least I’m getting A message indicating such rules. For those who may face this problem in the future I thought a picture might help explain where the failure occurs.

I’m off to purchase my Engine Ventilation Cooling Kit next week after confirming what others have said concerning the Taylor Extreme 409 wires. This is my third wire failure and this time I only got about 5,000 miles whereas with the stock wire/metal shields I was closer to 14,000 between failures. And yes, I’m out of warrantee based on time, not miles, as my coach now has 32,000 on it. I didn’t have a chance to examine the first wire, (replaced under warrantee), that failed but the last two failed/burned in exactly the same place, one being a stock wire the last being a Taylor 409. I was hoping the Taylors would outlast the stock and instead of playing with a cooling kit I would just swap out a wire every couple of years, WRONG!

I’ve been searching for post describing a homemade cooling vent someone posted here on IRV2 and would appreciate someone out there pointing me in the right direction. I’ll probably pony up for the Workhorse design but am curious what other do-it-yourselfers have done and how complicated it might be to put the kit in myself. I’m handy but a big chicken tackling new projects having done the wires myself a couple times now.

[a k]

Anybody try 8mm race car wires? They are supposed to hold up under extreme heat.

[Midniteoyl]

um..Do you know about InsulTherm?? Techflex - Insultherm Spark Plug Boot Insulating Sleeves

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[dieselclacker]

Paul,

Did the plug wire failure occur on the same cylinder each time? Number 5 (third plug back on drivers side of engine?)

Some on this forum have fabricated thier own version of the factory air kit that is available from Workhorse. You can do a search on this and see some pictures. All the kit does is pick up some cool air from outside the engine compartment, and direct it on the offending plug wire. You should be able to use some flexable dryer vent tubing to accomplish this.

Dieselclacker

[max49]

I used the 4" foil dryer tubing with a 4" heat register, or the ducting under the register for the air scoop. Contrary to what seems to be popular belief, my plug wires did'nt seem to burn from hard mtn. climbing , but more from stop & go driving. I put an inline 4" bilge blower (available at most any store with some marine accesories), switched to the dash for good air movement & cooling when I'm not moving fast enough to have air going through the tubing. All my failures have been with the # 5 plug wire, so I have no ventilation tubing going to the passenger side of the engine, not needed so far.

[Paul T]

Dieselclacker/max49
Yes dieselclacker it was the proverbial # 5 wire and I should have stated this on my first note. And max49 – I would love to see a snap shot of your handiwork. I know there are some pictures here on the forum of other homemade ventilation kits but my search hasn’t turned them up yet.
I probably went the wrong direction with putting on Taylor 409 wires. I had not noticed in the warrantee section of my Workhorse manual that spark plugs and spark plug wires are listed under the parts covered for 5 years/50,000 miles under Emissions Warranties Parts List. Silly me thought I only had 3 years/36,000 miles. Had I read this 14 months ago I would have just pulled into the local Workhorse provider. Next week I’ll have a talk with them. My brain says 5 years from Workhorse is a heck of a lot better than 90 days on the Taylor 409 wires. Also, I got a lot more miles off the OEM wires than the Taylors.
Just maybe Workhorse will give me the vent kit now or at the very least put some new wires on!

[max49]

Hmm, I did'nt know the plugs and wires were warrantied for 5 years either. I hear if WH has to replace enough of them , they give you the vent kit free; at least for some. However it still may be more of a hassle taking it in , going to pick it up than just doing it myself. I'll try to take some pics anyway and put them in Photobucket.
Her's the bilge blower I have.
RULE INDUSTRIES Waterproof In-Line Blowers at West Marine
It was easy enough to make; the problem is , how many miles or years does it take before I know it really fixed the burning problem?
I also was disappointed with the 409 wires. They looked pretty and beefy but they burned much sooner than my OEM style wires did.
When I had my engine changed, they asked me if I wanted them to put the 7- 409 wires that I had left on the old engine, on the new engine. I declined and had them put them in a bag for me.

[JC2]

Quote:

Originally Posted by Paul T Sorry to start a new burnt spark plug thread on this old topic but it seems one cannot reply with a photo to those post over 250 days old. At least I’m getting A message indicating such rules. For those who may face this problem in the future I thought a picture might help explain where the failure occurs. I’m off to purchase my Engine Ventilation Cooling Kit next week after confirming what others have said concerning the Taylor Extreme 409 wires. This is my third wire failure and this time I only got about 5,000 miles whereas with the stock wire/metal shields I was closer to 14,000 between failures. And yes, I’m out of warrantee based on time, not miles, as my coach now has 32,000 on it. I didn’t have a chance to examine the first wire, (replaced under warrantee), that failed but the last two failed/burned in exactly the same place, one being a stock wire the last being a Taylor 409. I was hoping the Taylors would outlast the stock and instead of playing with a cooling kit I would just swap out a wire every couple of years, WRONG! I’ve been searching for post describing a homemade cooling vent someone posted here on IRV2 and would appreciate someone out there pointing me in the right direction. I’ll probably pony up for the Workhorse design but am curious what other do-it-yourselfers have done and how complicated it might be to put the kit in myself. I’m handy but a big chicken tackling new projects having done the wires myself a couple times now.

Oemy's Web Site - Tech Tips

Qemy's Cold Air Kit

[Full-Timers]

Here are pictures of my Workhorse Vent kit installed.
Vent Kit Photos
Don’t waist your money on expensive plug wires. I, along with the Workhorse engineers back in 2004 tried several different plug wire designs until they installed the vent kit. The vent kit solved all the problems. Just be sure to direct the output of the vent directly at the faulting plug wires.

[Midniteoyl]

That still seems really silly to do when you can put firesleeves or similar on your boots... it can touch that exhaust then and not burn..

And, it you ARE gonna put in tubing, at least use the correct stuff:http://www.aircraftspruce.com/catalog/appages/scat.php

[JonBrazel]

The Workhorse Ventilation kit is definitely a good idea but if you want maximum protection we just rolled out a set of ceramic spark plug wires that will resist burning a lot better than even the Taylor Extremes.

[Floridakamper]

I thought I'd been following the "burnt plug wire" threads and for some reason didn't think the W-24 chassis was having this problem. I did put Taylor Extremes on my rig last year when I had a miss but the wires I took off were fine. I also replaced the fuel filter and cleaned the MAF sensor and the miss disappeared.

[Paul T]

Where is the MAF sensor located please and what maintenance schedule includes cleaning it?

And, while some of you professionals are answering questions, I’ve always wondered why a S. P. wire problem only exhibits symptoms, (missing), while under load. The first time I had the problem with just 9000 miles on the rig it only made itself apparent while accelerating through 4th gear like when you exiting a toll for example. Now, cruising along at 65 mph on a level stretch everything is great. But, starting up a small incline or pressing the accelerator to speed up will create the slight shutter/engine miss I have experienced.

I’m not a lawyer and stated on an earlier post that my manual indicated a 5 year/50,000 “Emissions Control Systems Warranties”, (and listed Plug Wires as a warranted part). That is on page 296 of my manual. Then on the next page it has “Emissions Control Systems Performance Warranty Coverage” of 2 years/24,000 for failing a test. So, ----------------------------.

And another question, --if all this lack of ventilation and burning plug wires is the fault of the coach builder and not the chassis builder why has not Workhorse avoided the issue and placed it squarely on the coach builder. Do they have some kind of under the table agreement on how this problem is to be solved?

[DriVer]

Quote:

Originally Posted by Paul T Where is the MAF sensor located please and what maintenance schedule includes cleaning it?

I have taken the liberty to provide the Maintenance Schedule below as an an attachment. There is no specific interval that is listed that calls for MAF sensor maintenance. That said, one should inspect the inlet tube for any contamination when the air filter is changed. Inspection of the MAF sensor may occur at this time. Be careful handling this sensor because it is easily damaged if mishandled.

Quote:

I’m not a lawyer and stated on an earlier post that my manual indicated a 5 year/50,000 “Emissions Control Systems Warranties”, (and listed Plug Wires as a warranted part). That is on page 296 of my manual. Then on the next page it has “Emissions Control Systems Performance Warranty Coverage” of 2 years/24,000 for failing a test. So, ----------------------------.

Workhorse will state that they are not obliged to provide warranty coverage if any after market components have been installed. Page 290, Topic "Tampering" . Therefore is you go to the Workhorse Service Center on an Emission Control basis they are not obliged to offer a remedy unless the engine is equipped with the stock AC Delco spark plug wires.

Quote:

And another question, --if all this lack of ventilation and burning plug wires is the fault of the coach builder and not the chassis builder why has not Workhorse avoided the issue and placed it squarely on the coach builder. Do they have some kind of under the table agreement on how this problem is to be solved?

Workhorse has offered remedy in all warranty cases where spark plug wires failed due to over heat. The CAVK was designed by Chris Christy from a NASCAR adaptation to cool rotors and developed by Workhorse to resolve a local spark plug over heat condition.

Not all motorhomes have exhibited failed plug wires and each instance it is handled on a case by case basis.
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