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    Thread: Coil pack Wiring harness?

    1. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      08-25-2009 08:39 PM #1
      I've got an appointment at the dealership to get a tsb taken care of. But now thinking about it... why would I pay them 340 dollars to replace a ground wire. Anyone know which wire on the coil pack harness is the ground so I can ground it with the rest of the grounds?
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

    2. Member nmjetha's Avatar
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      03 Jetta 2.slow
      08-25-2009 09:03 PM #2
      I second that, except mine is on a 03 2.0 not sure what yours is.

    3. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      08-25-2009 09:05 PM #3
      Mine is the same. Its such a simple fix and vw wants me to pay them a **** ton of money so they can cut my ground from my coil and make a new one and directly ground it. I just need to know which wire is the ground b4 I splice. Ya, Mine is 03 as well.
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

    4. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      08-25-2009 09:49 PM #4
      So I put my original coil pack back in my car as I replaced it with another oem unit 6 months ago. And what do you know... no more check engine light. And it runs way better, and its not misfiring like it was when I had it in the car b4 because I put electrical tape on the back of it. We'll see in the next couple days if that was the fix or not if the light comes back on.
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

    5. 08-25-2009 11:47 PM #5
      What are the codes you are getting?

      The ground wire on the coil harness is the brown wire. The TSB says to the ground wire should be cut and the coil end of it should be spliced to a new wire that runs to a ground lug underneath the battery.


    6. Member nmjetha's Avatar
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      03 Jetta 2.slow
      08-26-2009 08:22 AM #6
      I just ordered a brand new coilpack, mine should run like a champ after that. It does run a little rough with the code that comes and goes. Can't wait to swap that out and see.

    7. Member nmjetha's Avatar
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      03 Jetta 2.slow
      08-26-2009 10:12 AM #7
      My coilpack is the original, not sure how many miles they are good for. I got 86k on the clock how about u?

    8. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      08-26-2009 06:40 PM #8
      I had 58 on the clock when my coil went bad. I dunno about my issue. I'm going to bring the coil back an flip out about how my broken coil (micro fractures on the back cause misfires as it arcs to the block.) works better than the brand new one.
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

    9. 08-27-2009 12:56 AM #9
      Mine is original at 226k miles. It has some cracks around the plug wire connections but not arcing yet.

    10. 08-27-2009 04:21 PM #10
      What were the problems that got you to the TSB? My car (about 77K miles) is misfiring, especially at idle, and I've pulled P0303, P0351, and P0353 codes for cyl. 3 misfire and shorts at ignition coil A and C. I was going to swap out the coil pack and change the plugs and wires, but maybe I should check the ground first. I haven't seen any arcing from the coil.

    11. 08-28-2009 11:27 AM #11
      I believe open circuit codes for the ignition are indicative of a coil that needs a ground re-wiring. The intermittent open circuit will cause misfires so you would see codes for that too.

    12. Member nmjetha's Avatar
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      03 Jetta 2.slow
      08-31-2009 04:34 PM #12
      I know there is a TSB on the ground fix, but is it under warranty or a recall? Just wondering how much dealer would charge.

    13. Member nmjetha's Avatar
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      03 Jetta 2.slow
      08-31-2009 04:37 PM #13
      A diy thread would be awesome if someone decides to make one with pics.

    14. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      08-31-2009 05:32 PM #14
      The dealer wants 380 dollars to cut the brown wire on the plug that goes into the coil pack and run a new one off of it into the grounds under the battery box. Thats all it is. TSB is something that should be fixed but isn't under any warranty
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

    15. 09-01-2009 10:01 AM #15
      Holy crap!!!! That took me about 15 minutes to do. Mostly because you have to remove the battery and battery tray. How could they justify that amount?

    16. 09-01-2009 10:30 AM #16
      Quote, originally posted by nmjetha »
      A diy thread would be awesome if someone decides to make one with pics.

      I didn't take photos but it's very simple to do. This is how I did it though vw details in their tsb that a new wire with the proper terminal should be installed in the harness instead of cutting and splicing any wires.

      1) remove battery and battery tray
      2) remove harness from coilpack
      3) locate and cut the larger gauge brown wire (leave yourself enough room to strip the insulation back and crimp or solder a new ground wire)
      4) crimp or better yet solder a new wire of equal gauge (i don't know what gauge it is) about 2 or 3 feet long.
      5) run the wire along the same path as the main engine harness bundle that runs above the starter.
      6) Cut the wire with enough room plus some slack to reach the far right ground lug under the battery tray.
      7) crimp a ring terminal connector like this one http://www.autotoys.com/pics/y...1.jpg
      8) remove the far right ground lug nut under the battery tray
      9) slide the ring connector on the new ground wire to the ground lug. (if possible, snap the terminal connector in to the plastic clip ring around the ground lug)
      10) put everything back together and clear your dtc's.


    17. Member nmjetha's Avatar
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      03 Jetta 2.slow
      09-01-2009 10:43 AM #17
      So, the cel codes are caused by a groundwire exposure. Weird how does this happen, or could it possible be the groundwire is not screwed down tight under the battery?

    18. Member elRey's Avatar
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      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      09-01-2009 10:48 AM #18
      No, the DTCs are caused by a weak ground... er a shared ground. The fix is to break out the ground for the coil and have it go directly to the chassis/engine.

    19. 09-01-2009 11:21 AM #19
      Apparently there was a design or manufacturing flaw affecting a lot, if not all of AVH code engines. It might have affected other engine codes too but this is the one I have and is referred in the TSB.

      Basically you are bypassing the existing ground wire with a new one directly to the main ground terminals under the battery. This has fixed my open ignition circuit and intermittent misfire problems.


    20. Member nmjetha's Avatar
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      03 Jetta 2.slow
      09-01-2009 01:34 PM #20
      Nice, any links to the TSB around the web? Still wondering why no recall on this, makes no sense at all? Hope to fix mine soon.

    21. 09-10-2009 06:01 PM #21

    22. 09-10-2009 07:44 PM #22
      That's for the 1.8t not for the 2.0 but I think the idea is the same.

    23. Member nmjetha's Avatar
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      03 Jetta 2.slow
      09-13-2009 11:06 AM #23
      Before I tackle this somewhat easy vw wire fix. What gauge is the coilpack ground wire???


    24. Member nmjetha's Avatar
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      03 Jetta 2.slow
      09-16-2009 12:01 PM #24
      Anyone at all so, I can tackle this ground fix on my 2.0, know what gauge it is????

      thanks


    25. Member nmjetha's Avatar
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      03 Jetta 2.slow
      09-16-2009 03:11 PM #25
      Dumb question, but how much of the ground wire did you cut off???? Right next to the harness or what?

    26. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      09-17-2009 08:24 PM #26
      Hey hey... I did mine yesterday. I bought a new coilpack plug and a section of wire with the spade plug that goes into the coil plug for $15 from the dealership. I got an extra one with the spade and wire attached. I can take that, put a butt connector on it, heatshrink it, and put a ring terminal on it and heatshrink it for you so you can do what I did. Just send me $20 an I'll send you the wire the same length as I did mine. BTW the wire is 12 gauge.
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

    27. Member nmjetha's Avatar
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      03 Jetta 2.slow
      09-17-2009 08:44 PM #27
      Hmmm if I go to the dealership what do I ask for, or do you have a part number or pic of this concoction? I don't know if sending a stranger $20 is the best idea.

      thanks


    28. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      09-17-2009 08:52 PM #28
      I threw the receipt out, but what I did was go up to the parts counter. I asked them to pull up the diagram of the coil pack. I said i needed to get the 12 gauge wire with a new spade to replace a ground in it. He went out back, came back with a couple different wires, what you want is the medium sized one in the computer. Its a yellow wire with a spade end (the one that goes into the coil plug. I bought two of them. Then I bought some 12 gauge wire at advanced auto. A package of weatherproof heatshrinkable butt connectors and ring terminals. You pull the coil plug off... look inside, push the purple piece out of the plug. Then you push the spade out with a small flathead screwdriver or you can pull the wire carefully. You crimp and heatshrink the wire with spade to the spoiler of wire. Run the wire through the wire loom to under the battery box. Cut the excess wire. Then you crimp and heatshrink a ring terminal on the end, loosen one of the grounds, install the new ring terminal and tighten the ground back up. Put the purple part back into the coil plug and reconnect the coil pack. Oh forgot to include removing the battery/battery box part in there. But thats pretty much it. CEL free and the car sees to have a tiny bit more acceleration.
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

    29. 09-17-2009 10:19 PM #29
      Thanks guys gonna try this tomorrow. I've been fighting this problem for a while....after changing the spark plugs wires and coil...the problem still seems to come and go. I was actually starting to think it might have been a fuel issue. Hopefully tomorrow the problem will be fixed!!!

    30. Member nmjetha's Avatar
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      03 Jetta 2.slow
      09-17-2009 10:20 PM #30
      Sounds confusing, I am gonna try it also.

    31. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      09-17-2009 10:43 PM #31
      haha so easy... you could simply cut the brown wire, butt connector it to a 12 gauge peice of wire, and run it to the grounds under the battery box... simple as hell. I just went and did it to spec...
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

    32. Member nmjetha's Avatar
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      03 Jetta 2.slow
      09-19-2009 10:40 AM #32

      Sorry, but I have no idea where my ground wire is that is the harness above. HELP


    33. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      09-19-2009 04:50 PM #33
      Thats the harness. You pull the top cover of it off, find the brown 12 gauge wire, and proceed as stated above.
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

    34. Member nmjetha's Avatar
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      03 Jetta 2.slow
      09-19-2009 09:19 PM #34
      I see that little clip opens up on that connector, thanks will do this tomorrow. Too bad there wasn't a way to remove entire wire out of the inside, or is there? I will just cut and butt connect it. Kinda odd to run it straight to the battery, not sure where that brown wire really goes inside that plastic covering all the wires, oh well.

    35. Member Brightgolf's Avatar
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      01 Wolfsburg Jetta
      09-20-2009 08:38 AM #35
      I told you there is a way to take it out. The purple piece on the inside of the plug sides out the side. then you pull the brown wire. That why I offered to sell you the wire with the connector that slides in place of the brown wire. And the wire doesn't go to the battery, it goes under the battery box, you remove the battery and the four 10mm bolts that hold the box down. You will see a couple nuts holding some wires down. You put the wire from the coilpack on one of these. make sure you do it right, with heatshrink butt connectors and heat shrink ring terminal.


      Modified by Brightgolf at 8:40 AM 9-20-2009
      01 Wolfsburg Jetta 5 Speed | Apr Stage 2 | Stage 1 Clutch + 14lb flywheel | Neuspeed Short Shifter | 3" turboback exhaust | Forge 007 | Forge TIP | Eurojet Discharge piping | Sidemount | Eurojet pcv hoses | Blackforest Stage 1 Mounts | Raceland Coilovers | Newsouth Boost Gauge | Neuspeed P-Flo | 4 Pot Brembos

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