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    Thread: REFERENCE: 1.8t Coil Pack Replacement, Repair, and Heat Shields

    1. Moderator groggory's Avatar
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      06-11-2010 06:46 PM #1
      There seems to be a lot of different methods of working on the coil pack problem so I'm going to take a stab at making a definitive reference. Please chime in if I post any misinformation, partial information (chime in with further info), or additional products or links that may be useful.

      Note: I will be editing and adding extensively to this post as I get all my information together.

      Coil Pack Harness Replacement/ Repair Kits

      INA Engineering 4 wire Coil
      7/31/09 - $187 shipped
      * Splice into the factory harness
      * Does not go all the way back to the ECU
      * Uses Superior Wire quality to prevent the cracking issue from resurfacing
      * Uses flex boots similar to what is found on the 2.0t to prevent cracking at the connectors
      * Does not cover up any of your coil pack area. Easy to work on coil packs


      USP Motorsports individual Coil Pack Replacement
      6/11/10 - $39
      * Splices into the factory harness
      * Does not go all the way back to the ECU
      * Uses superior wiring to OEM


      Coil Pack replacement harness
      6/11/10 - $50.27
      * OEM part
      1J0 971 658 L
      * Replaces the harness all the way back to the ECU
      * You will need tools to de-pin the ECU


      Home-Made Version of the tool pictured above for repinning

      It is two safety pins taped together. Apparently works fine and may just save you in a pinch.

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      Coil Pack Heat Shields
      034 Motorsports Coil Cover
      6/14/10 - $30
      * Bolts to back of valve cover
      * Available in: Raw stainless, Brushed stainless, or powdercoated
      * Requires some trimming


      ECS Heat Shield
      6/11-10 - $65.01
      * OEM Part #
      8L9 121 659
      * Uses snaps to button it up around the coils and wires
      * Covers the wires of all the coil packs like a flap.
      * Uses OEM style heat shield material


      Coil Pack Cover off MkV 2.0t
      4/28/10 - $18.89
      Part # 06F 971 824C
      * Can fit the 1.8t coil pack loom with a little trimming
      --My personal choice (shown w/ INA 1.3 spacers and TSI coils)




      Ignition Coil Pack Shield
      6/11/10- $58.95
      * Appears very similar to the ECS heat shield


      1.8t coil pack rubber boot
      Part # 4B0906102 (for 2 pin/ injector)
      Part # 4A0906102 (for 4 pin/ coil pack)
      4/28/11 - $4.25 / $6.11



      The Audi OEM heat shield is P/N is 8L9-121-659
      Price ????



      Custom cover by forum user 'goodhews'
      4/19/10 - $15
      * Made of a mild steel
      * Covers coil packs and wiring
      * Attaches using bolts on back of valve cover


      Heat Reflective Tape
      ~$15
      Wrap your wiring in this and it will dodge most of the heat.
      Wrap your wiring in this and also buy the rubber boots for your coil pack connectors and I think you'd be pretty golden.


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      DIY Links for Coil Pack Repair

      How to install the foil snap type shield
      How to repin the ECU and do a full rewire of the coil packs

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      Coil Packs

      * 4 Bolt Style
      Part #
      Price
      Distributor

      * 1.8t Push Down Style
      Part #
      Price
      Distributor

      * Conversion to mk5/mk6 pushdown style
      The use of the mk5 or mk6 pushdown coil is a new trend in the 1.8t tuning community which has shown to create a stronger spark and has allowed the use of a larger spark plug gap. This larger gap allows for a better burn and thus improved fuel economy, improved engine idle, and the ability to use more aggressive timing which will result in more power.

      The mk5/6 coils will push straight into any 1.8t valve cover as is, but they will stick out the top significantly. This installation makes long term reliability questionable at best. To meet this demand a few aftermarket shops have created billet adapters to adapt the various 1.8t valve covers to fit these coils.

      Long term reliability of mk5/mk6 coils in a 1.8t platform is not yet known, but as of this writing these coil packs have usurped the famed 'Hitachi Bolt Downs' as the coil to get for the 1.8t platform.

      On a side note, mk5/6 coils are less expensive than Hitachi Bolt Down Coils. The caveat to this is that adapter plates are really required to make a proper seal and fit.

      Mk5/6 coil packs are compatible with all 1.8t motors that utilize a 4 pin coil pack harness. The 3 pin harness in early 1.8t motors is not compatible with the mk5/6 coil packs.

      Bolt Down Plates

      * IE Plate for all 1.8t valve covers
      $69.99 for all four adapters w/ mounting hardware


      * 034 Plate for square 4 bolt style valve covers

      * 034 Plate for 2 bolt style push down valve covers


      Coil Packs

      VW/Audi Mk6 Coil Pack (Revision F)
      Part # 07K905715F
      Price: $18.95
      Distributor: partshaus.com


      Mk6 Coil Pack
      RED MKV FSI Coil Packs - 06E 905 115
      BLACK MKV FSI Coil Packs - 07K 905 715 F
      BLACK MKV TSI Coil Packs - 06F 905 115 F
      BLACK MKVI TSI Coil Packs - 06H 905 115

      Eldor Mk4 Coil Pack (version ??)
      Distributor: IE
      Part #:
      Price: $29.99


      'E' Bolt Down Coils

      * OEM Part #
      Distributors
      Price

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      Related

      Coil Pack Guide
      Last edited by groggory; 11-11-2011 at 07:34 PM.

    2. Member sounrealx's Avatar
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      06-11-2010 08:24 PM #2
      Nice post groggory

      This will simplify a lot of the confusion about the differences between replacement options. I'm also thinking now that i should get a shield to dress up the bay.

    3. Moderator the brit's Avatar
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      06-14-2010 12:36 PM #3
      Nice
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      06-16-2010 11:49 AM #4
      good post. I still don't understand the idea of putting a metal shield over your valve cover. You would think that would keep the heat in and cause the wires to crack sooner. They do look nice though.

    5. Moderator groggory's Avatar
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      06-16-2010 01:59 PM #5
      Quote Originally Posted by liquidvw View Post
      good post. I still don't understand the idea of putting a metal shield over your valve cover. You would think that would keep the heat in and cause the wires to crack sooner. They do look nice though.
      I think the metal shield would protect against direct radiated heat from the exhaust manifold/ turbo..which is the biggest killer.

      I think of it this way...If I put meat in the broiler, what happens when I cover it with aluminum foil and what happens when I leave it open? Open = crispy delicious outside (dead coil wires). Closed = Very hot meat but soft and juicy. But even with that said, I think the OEM style heat shield is still the right way to go. I have no data to back this up. We need to get someone in there with a thermocouple and take readings at a few different spots over various driving conditions.

    6. Moderator groggory's Avatar
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      07-06-2010 02:22 PM #6
      Updated with DIY link for full replacement (aka the ECU full wiring harness in my initial post)

    7. Moderator groggory's Avatar
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      04-28-2011 03:00 PM #7
      Hey look, I found an old FAQ thread I made back in the old good ol days.

      So free ^^bump^^ for me
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    8. 04-28-2011 07:37 PM #8
      Stole this pic but it's an MKV coilpack harness cover which fits mkiv's with minor trimming

      part num: 06F 971 824C
      Last edited by dknl; 04-28-2011 at 07:40 PM.

    9. Member Andaloons's Avatar
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      04-28-2011 07:54 PM #9

    10. Member JWoody's Avatar
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      04-28-2011 07:58 PM #10
      ^^^ It sure does. Nothing a Dremel can't handle. Greg, pick which ones to go up above and afterward I'll delete this Post like the W/M one.

      -J




    11. Moderator groggory's Avatar
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      04-28-2011 10:16 PM #11
      Do you know what the difference is between those two grommets?
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    12. Member Andaloons's Avatar
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      04-28-2011 10:26 PM #12
      Quote Originally Posted by groggory View Post
      Do you know what the difference is between those two grommets?
      I think one is for 2 pin (injectors) and the other is 4 pin (coilpack.)

    13. Moderator groggory's Avatar
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      04-28-2011 10:28 PM #13
      Quote Originally Posted by Andaloons View Post
      I think one is for 2 pin (injectors) and the other is 4 pin (coilpack.)
      That's rad! I want to buy a set!

      How hard is it to de-pin the injectors so I can get the wires through that little hole? This would look super nice!
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    14. Member Andaloons's Avatar
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      04-28-2011 10:33 PM #14
      Quote Originally Posted by groggory View Post
      That's rad! I want to buy a set!

      How hard is it to de-pin the injectors so I can get the wires through that little hole? This would look super nice!
      I have not ordered them yet. Back on ECS it looks like they are 4pin. Hmmm... gotta find the right ones for the injectors!

    15. Member Andaloons's Avatar
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      04-28-2011 10:35 PM #15

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      04-28-2011 10:49 PM #16
      groggory i really want pass by & drop u a fancy beer case
      thank you for such informations,to you and all who enrich our knowledge

    17. Moderator groggory's Avatar
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      04-28-2011 10:58 PM #17
      Quote Originally Posted by ModsTTand View Post
      groggory i really want pass by & drop u a fancy beer case
      thank you for such informations,to you and all who enrich our knowledge
      No problem man.

      I'll take one of these...


      or



      :-) I love beer. Beer loves me.

      But seriously. No problem. I hope these faq things help people.
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    18. Member Andaloons's Avatar
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      04-28-2011 10:59 PM #18
      Yum! IPAs are my favorite.

    19. Member bootymac's Avatar
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      04-29-2011 01:13 AM #19
      A cheap solution is to wrap the wiring harness with heat reflective tape:


    20. Member NOLA_VDubber's Avatar
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      06-06-2011 05:03 PM #20
      Are you guys who've replaced the whole wiring harness noticing cracks all the way back to the ecu? Based on the level of PITA associated with changing the whole thing I think I may just take the INA route.

    21. Member
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      06-06-2011 08:25 PM #21
      You rule.

      I need 2 of those heatshields. The audi part is stupidly expensive.

    22. Moderator groggory's Avatar
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      06-06-2011 09:26 PM #22
      I have an unused ina repair harness for sale.
      fyi
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      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    23. Member mcgyver7923's Avatar
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      07-20-2011 09:39 PM #23
      Quote Originally Posted by groggory View Post
      I have an unused ina repair harness for sale.
      fyi
      How much for that? Great thread! What problems occur when the wire insulation starts to crack?

      Thanks,
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    24. Moderator groggory's Avatar
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      07-21-2011 02:58 AM #24
      Quote Originally Posted by mcgyver7923 View Post
      How much for that? Great thread! What problems occur when the wire insulation starts to crack?

      Thanks,
      Sorry...already sold.

      When the wire insulation starts to crack you will get more misfires and weaker spark...which causes misfires and partial burns ... which causes carbon buildup in your cylinders, valves, exhaust manifold, turbo, o2 sensors, and exhaust. Lots of there.

      If you can see the wires becoming brittle, cracking, or just not in good repair...just replace them. It'll save you headaches when you wonder what the real problem is down the line.

      Also, cracked insulation can make the coil packs work harder, thus burning them out and costing you money.
      My Build
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      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    25. Member Andaloons's Avatar
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      07-21-2011 07:58 AM #25
      Should you add the new 2.0t coilpacks and adapter plates to this thread?

    26. Moderator groggory's Avatar
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      07-21-2011 08:13 AM #26
      Quote Originally Posted by Andaloons View Post
      Should you add the new 2.0t coilpacks and adapter plates to this thread?
      Thanks. I started it up in the top post. I'll fill in some blanks later and get you guys to proof it.

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      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    27. Member NOLA_VDubber's Avatar
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      07-21-2011 09:11 AM #27
      I ended up buying an OEM harness for $50, then just cutting and splicing it in instead of running the new wires back to the ecu; I didn't want to fu(k with de-pinning those plugs.

      Anyway, no more misfires! I can now run BKR7E's gapped to 0.030 with stock coilpacks and not get misfires (before I had to keep it down to 0.026).

    28. Moderator groggory's Avatar
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      07-21-2011 03:49 PM #28
      Quote Originally Posted by NOLA_VDubber View Post
      I ended up buying an OEM harness for $50, then just cutting and splicing it in instead of running the new wires back to the ecu; I didn't want to fu(k with de-pinning those plugs.

      Anyway, no more misfires! I can now run BKR7E's gapped to 0.030 with stock coilpacks and not get misfires (before I had to keep it down to 0.026).
      If by chance you have your old harness, could you post up pictures of problem areas on the wires? It seems a common question is "what do cracked wires look like"
      My Build
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      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    29. Member NOLA_VDubber's Avatar
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      07-21-2011 04:22 PM #29
      ^I'll dig it out of the trash later on and take a look. I wanted to disect it anyway.

    30. Member LGDUBR's Avatar
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      07-21-2011 05:12 PM #30
      Excellent info, great writeup!
      04.5 BMP GLI 1.8T
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    31. Moderator groggory's Avatar
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      11-11-2011 07:35 PM #31
      Bump for attention whore status

      ^^ Updated some part numbers
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    32. Junior Member
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      12-07-2011 08:13 PM #32
      Quote Originally Posted by NOLA_VDubber View Post
      ^I'll dig it out of the trash later on and take a look. I wanted to disect it anyway.
      did you ever dig the old harness out of the trash and examine it?

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      12-07-2011 09:47 PM #33
      For those guys running the IE coil adapters with 2.0T coils, is there a preference or difference between the FSI and TSI coils?

    34. Moderator groggory's Avatar
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      12-08-2011 12:16 AM #34
      Quote Originally Posted by cjb88 View Post
      For those guys running the IE coil adapters with 2.0T coils, is there a preference or difference between the FSI and TSI coils?
      Issam @ INA said he prefers the metal bodied ones.
      My Build
      My FAQ / DIY Thread -- Look here for 90% of the questions you have

      Welcome to the world of racing! Budgets are ALWAYS exceeded, deadlines are never meet, end-goals never reached, and wives always unhappy... it's all worth it though!

    35. Member
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      12-08-2011 12:45 AM #35
      Quote Originally Posted by groggory View Post
      Issam @ INA said he prefers the metal bodied ones.
      Excuse my ignorance, but which ones are the metal bodied ones?

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