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View Full Version : Another AEB 2.0T FSI Coil Upgrade



B6T
02-19-2013, 04:39 PM
As you guys know there are already a couple very reasonable options on the market for upgrading your AEB 1.8T with the 2.0T FSI coils. 034 Motorsports (http://www.034motorsport.com/ignition-solutions-coil-conversion-icm-delete-kit-early-18t-to-20t-fsi-coils-p-22290.html) sells a very nicely made component set. ECS Tuning (http://www.ecstuning.com/Volkswagen-Jetta_IV--1.8T/Engine/Ignition/ES7679/) sells a replacement coil harness intended for the Mk4 1.8T which can be spliced into the existing AEB harness. The first option is very simple to install, but comes at a higher cost. The second option is much cheaper, but you need to hack apart your engine harness to install.

I took a third and different approach that I haven't yet seen. My thoughts is that it would be cheaper than both mentioned and in-between in terms of difficulty and amount of work. My approach was to simply replace the existing 3-pin plugs with the new coil 4-pin plugs. Below is the process I followed, and the pros and cons of doing it this away.

Here are the parts I used:

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_150637_zps10558ec0.jpg


To start, I more or less followed this wiring diagram here (http://www.audigeeks.com/images/tech/coilpacks/ICM_Delete.jpg), except with a few exceptions noted below.


When I started:

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_135545_zps816b080b.jpg


Snipped off the old connectors, leaving each wire identical in length (cut perpendicular to connector edge):

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_150344_zps68ced0dd.jpg


All connectors snipped off, and also the point where I realized this may have been a bad idea given that I needed to get to work the next day:

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/70759684-14de-47df-98ae-1d4f9a6c11b7_zpse4b39a85.jpg


New terminal pins crimped (and soldered) on:

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_162621_zpsb49f11d6.jpg

Where it says on the wiring diagram to bridge pins 2 and 4 together, I actually retained the Brown/Yellow ground from the 3-pin coil and connected it to pin 4 on the new coil. I then ran coils 1 and 2, and 3 and 4 to their own ring terminal and connected it to the M6 stud between cylinders 3 and 4.


New plugs, boots, and ground harness installed:

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_182045_zps7304622f.jpg


Unplugged the power output stage (ignition control module) and spliced the wires together:

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_200256_zps1963f633.jpg


Finished product:

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_200304_zpsf637b834.jpg

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_200320_zpsc0d96599.jpg

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_200330_zps9414b212.jpg


The car fired up right away (thankfully) and I instantly noticed a smoother cold idle. The engine also feels much smoother under cruising. Under high throttle I noticed an elimination of misfires. I can compare it to the difference in feeling of a cold engine vs. one that is heated up, or one that is newer vs. one that is older and worn/noisy. Now all I need is a set of the coil adaptor plates to finish it off.

Pros of doing it this way:
- cleaner looking.
- cheaper ($25 for the plugs and terminals, maybe $5 for miscellaneous solder and heat shrink, $90 for the coils).

Cons:
- crimping the terminals on is very tedious and you need to have special (and expensive) terminal crimp pliers.
- certain wires in your harness will most likely be cracked due to age.

If I did it all again, I would probably go with the harness from ECS since I found a few cracked wires that needed to be replaced. But I was at the point of no return and needed to get the car back together for the drive to work. However, if your harness is in good shape, and you are skilled with the appropriate crimp tool, than you may find that this approach is ideal for you.

TConklin821
02-19-2013, 04:44 PM
Nice write up man, very well done. What plugs and gap are you running?

Corrado_Guy
02-19-2013, 04:47 PM
Great job, a few others have done it similar to this but yours looks top notch. I would recommend the coil adapters to close the holes around the coils but otherwise it is a great plan and looks like it worked out well.

Mad Cow
02-19-2013, 09:50 PM
If you feel like being a guinea pig, you might be able to use Touareg coil adaptors instead of pointlessly expensive aftermarket options. The adaptor is 077905390 (http://www.ecstuning.com/Search/077905390/ES283074/) and there's also a seal which you might want 058905261A (http://www.ecstuning.com/Search/058905261A/ES2538146/).

Gearheadjarrod
02-19-2013, 11:48 PM
Where did you source the plugs?

vtraudt
02-20-2013, 03:54 AM
AIf I did it all again, I would probably go with the harness from ECS

I followed you advise, but are baffled with ECS 1J0971658L Golf harness in hand. No pin out or diagram from the harness. Not sure which looms to use, which to discard.

Looking for simple diagram to hardwire the 1J0971658L.

Need:
- pin out of the ECU to ICM 5 pin connector (4 'signals', center pin (forgot if +12 or ground?))
- pin out of the 1J0971658L Golf harness or pin out of Bosch coils connector (and can then trace the 4x4 wires in the harness)

mysman
02-20-2013, 08:33 AM
If you feel like being a guinea pig, you might be able to use Touareg coil adaptors instead of pointlessly expensive aftermarket options. The adaptor is 077905390 (http://www.ecstuning.com/Search/077905390/ES283074/) and there's also a seal which you might want 058905261A (http://www.ecstuning.com/Search/058905261A/ES2538146/).

As you know, there is still a question of how to seal the spark plug hole from dirt and water, since the Touareg adapters are rounded and don't completely cover the square VC hole on the AEB/ATW. That O-ring you've linked won't really help. The Touareg coils, however, have a rubber grommet on the spark plug extension that is used to plug the hole, no pun intended.

cruciform
02-20-2013, 11:41 AM
where did you buy the 4 pin connector and rubber boots? Do you have a parts/part numbers list?
Want to do this as well...

B6T
02-20-2013, 12:43 PM
Need:
- pin out of the ECU to ICM 5 pin connector (4 'signals', center pin (forgot if +12 or ground?))
- pin out of the 1J0971658L Golf harness or pin out of Bosch coils connector (and can then trace the 4x4 wires in the harness)

Both can be found in the wiring diagram that I linked to in my previous post. The ICM connectors are there and it also shows how to jump the wires. The thick brown wire, #3 on the 5 pin connector, is a ground and is unused after the ICM delete.

As far as the Golf harness, I can't advise what wires to eliminate since I have never done this method and I don't want you to wreck your harness.

034Motorsport
02-21-2013, 10:23 AM
Looks great, we always support people DIY! Thanks for the link too.

As a head's up, besides selling a Plug n Play FSI conversion like you listed, we also have a repair harness that combines our normal 1.8T Repair Harness with our FSI upgrade, and only for a bit more than the normal kit: http://www.034motorsport.com/ignition-solutions-repair-harness-coil-conversion-icm-delete-early-18t-to-20t-fsi-coils-p-22296.html

We also sell all the parts necessary to do your own wiring like B6T did if anyone needs help sourcing the connectors.

We even have a 034Motorsport exclusive 5 pin male rectangle connector, available on its own or our ICM Delete harness is available on its own, separately from the FSI adapter harness.

c0r3y.af
02-21-2013, 10:39 AM
Looks like it came out pretty well. Nice work! [up]

SpeedWorksAuto
02-22-2013, 09:54 AM
In for the new pictures.....[:D]

dmoua68
02-22-2013, 12:09 PM
where did you buy the 4 pin connector and rubber boots? Do you have a parts/part numbers list?
Want to do this as well...
THIS

Also when you say
I then ran coils 1 and 2, and 3 and 4 to their own ring terminal can you be more specific?

cruciform
02-23-2013, 01:47 AM
THIS

Also when you say can you be more specific?
I asked above, and sent the original poster an email, have yet to hear back. I'd really like to find the necessary parts and build this.

B6T
02-23-2013, 02:29 PM
Here (http://shop.vems.hu/catalog/active-connector-p-169.html) is where I got the connectors. They aren't OEM VW/Audi though but aftermarket replacement.

B6T
02-23-2013, 02:32 PM
Also when you say can you be more specific?

The brown/yellow wires from cylinders 1 and 2 are tied into one ring terminal, and the brown/yellow wires from cylinders 3 and 4 go to another ring terminal. Both are grounded to the engine on the M6 stud between cylinders 3 and 4. Take a look:

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_200330_zps9414b212.jpg


I'd make a wiring diagram but I'm too lazy.

Steve Chicago
02-23-2013, 05:57 PM
With the angle your coilpacks are facing, the plastic Touareg adapter plates and the metal INA adapter plates won't work without a slight change. The plates are "keyed" and won't allow the coil to go in at that angle. You could rotate the coils to the original vertical angle if your harness length allows and use the INA plates. Or you could cut/file off the key on the coil to allow a pack to be inserted at any angle.

http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_200330_zps9414b212.jpg

http://c1552172.r72.cf0.rackcdn.com/367735_x600.jpg

http://i226.photobucket.com/albums/dd25/issamabed/06A-18T-20TCoilPackadapter-V13.png

dmoua68
02-23-2013, 06:04 PM
The brown/yellow wires from cylinders 1 and 2 are tied into one ring terminal, and the brown/yellow wires from cylinders 3 and 4 go to another ring terminal. Both are grounded to the engine on the M6 stud between cylinders 3 and 4. Take a look:


I'd make a wiring diagram but I'm too lazy.

Sweet thanks! I have to do this now!

ZimbutheMonkey
02-23-2013, 07:29 PM
Nice job OP [op] the only difference in mine is that I ended up deciding to run each plug it's own ground. If you look on the valve cover there should be a 10mm threaded hole next to each of the plugs (probably for some line or emissions thing I eliminated along the way lol). I just used those to ground each plug. I figure it was probably best. That way if I was getting a ground issue at least it would be tied to only one cylinder for easier diagnosis.

B6T
02-24-2013, 10:02 AM
^Good point about diagnosis! I went with two just to keep it clean. I would have went with one, but I couldn't stuff 4 wires into one ring terminal crimp end.


With the angle your coilpacks are facing, the plastic Touareg adapter plates and the metal INA adapter plates won't work without a slight change. The plates are "keyed" and won't allow the coil to go in at that angle. You could rotate the coils to the original vertical angle if your harness length allows and use the INA plates. Or you could cut/file off the key on the coil to allow a pack to be inserted at any angle.

That's a really good point that I didn't consider! Thanks for pointing it out! I doubt there is enough slack in the harness to angle the coils at 90deg so I'll likely grind the tab off the coil. I think I'd go with the Touareg plates since they are cheaper and more simple.

SpeedWorksAuto
02-24-2013, 01:58 PM
Oh, wait. Someone posted a picture of your setup somewhere else asking about some angled adapters. I thought it was you, but after reading guess not. I am not trying to get in trouble over here but:

http://forums.vwvortex.com/showthread.php?5893611-2.7TT-coilpack-adapter-flanges-for-2.0T-coils/page3

almost to the bottom of page three, and results on the next page.

Steve Chicago
02-24-2013, 07:14 PM
Your necessity became the mother of invention (or modification).

vtraudt
03-09-2013, 05:02 PM
Did the FSI coils (red Bosch) and ICM delete on my AEB. I wired the signal from the ECU to each coil. Common +12V (4 individual wires from coils to 4 wires from car).
4 thick grounds from coils and 4 'signal' ground wires to common connector, ground to valve cover and ground to ECU ground.
ICM removed.

Integrated Engineering red spacers.

I left the gap at 0.030 for now (NGK BKR7E).

Battery was disconnected for a week. Have not entered radio code yet.

Cranks, fuel smell. No fire.

Took the plugs out and laid on valve cover. NICE, fat spark, dancing from one to the other coil.

Back in. Pushed the coils down real hard (someone said they take quite a bit of force). Crank. Nothing.

Back out. New plugs on valve cover. Nice spark.

Removed the spacers. Put coils on without spacers. Crank. Nothing.

The coils 'snap' onto the plugs. But not sure how deep they should go. Currently, I have 25mm space from coil to cylinder head.

Can someone confirm that this is the correct height? Spacers are 10mm thick, to for those with spacers, gap would be 15mm.

Other suggestions? Fuel pressure is there, gas in the tank.

Anything else that would show:

- sparks with plugs out and on valve covers
- no fire
- fuel pressure ok


http://i853.photobucket.com/albums/ab91/vtraudt/1998%20Passat%20Big%20Guy%20John/IMG_0001_zps7acb4691.jpg

Mad Cow
03-09-2013, 05:49 PM
Maybe you mixed up the signal wires, that way you'd be getting perfect spark but at the wrong time. .

vtraudt
03-10-2013, 05:22 AM
Maybe you mixed up the signal wires, that way you'd be getting perfect spark but at the wrong time. .

Certainly possible (would expect some weird detonations though, like mixing up ignition wires?).

I connected (and traced):

ECU connector ECU pin ECU color ICM pin FSI coil Coil loction car
T80/70 #70 Grey-Yellow T5/1 Pin 1 Front 1
T80/78 #78 Yellow-Grey T5/2 Pin 1 Front 2
T80/77 #77 Red-Grey T5/4` Pin 1 Front 3
T/8071 #71 Green-White T5/5 Pin1 Rear

Was told coil 1 is most forward coil, coil 4 is most rearward.

Schematic below (from Hayes book?).
Pin out ECU plug below (for tracing).

http://i853.photobucket.com/albums/ab91/vtraudt/HessenTurbo/AEBICMcoilswiringzoom_zps0aa40bbe.jpg
http://i853.photobucket.com/albums/ab91/vtraudt/AEBECUpinout118596839vc4_zps36f992f0.gif

vtraudt
03-10-2013, 12:07 PM
Double checked:

ECU signal goes to pin 3 on coil connector.
Pin 1 has +12V with ignition on.
Pin 2 and pin 4 have ground.

Ignition sequence (see video with spark plugs on valve cover) is 1-3-4-2.

http://i853.photobucket.com/albums/ab91/vtraudt/th_FSIcoilssparksequence1-3-4-2_zps90fbb19f.jpg (http://i853.photobucket.com/albums/ab91/vtraudt/FSIcoilssparksequence1-3-4-2_zps90fbb19f.mp4)

Also so thread stating 1-3-2-4, rewired and tried.

http://i853.photobucket.com/albums/ab91/vtraudt/th_FSIchangedsparksequence1-3-2-4_zps6d22764a.jpg (http://i853.photobucket.com/albums/ab91/vtraudt/FSIchangedsparksequence1-3-2-4_zps6d22764a.mp4)

Ninja546
12-29-2015, 09:35 PM
In the Image where the ICM is: What every happened to the wire 3/5?
On the "Triggers" on the Pre side its a 5Pin plug

Basicaly,, it seems you didn't cover the ICM area that well, and based on picture.. Did you just connected the wires across to the 4Pin plug (the Post) side?

other then that,, great pics, clean set up..

Hope to hear more input on the ICM side of things... thnks

Ninja546
12-30-2015, 12:42 PM
There in the Pic you can see,, he ran two sets of ground to the Valve Cover (VC)... those two wires are a combo of 1/2 and 3/4.

vtraudt
12-31-2015, 06:07 AM
In the Image where the ICM is: What every happened to the wire 3/5?
On the "Triggers" on the Pre side its a 5Pin plug

Basicaly,, it seems you didn't cover the ICM area that well, and based on picture.. Did you just connected the wires across to the 4Pin plug (the Post) side?



ICM is 5 to 4 pin IIRC. Not sure what the pin out for the incoming 5 and outgoing 4 is. If that is the picture: http://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_200256_zps1963f633.jpghttp://img.photobucket.com/albums/v50/b6tfestiva/A4%20Coil%20Conversion/20130217_200256_zps1963f633.jpg

maxiz1
01-03-2016, 08:38 PM
I too need clarification on the wiring at the ICM side. If I understand this correctly, the signal from ECU should be jumpered directly to the respective coil output stages. So pin 1,2,4,5 at the 5 pin side should connect to pin 1,2,3,4 at the 4 pin side.

But then what happens to the middle pin no 3 (ground) on the 5 pin side?

Edit: One additional question. Has anybody run the upgraded coid set without touching the ICM? Basically, my ICM is still ok.

Avant Nate
01-03-2016, 09:02 PM
What most of us did, not using a premade jumper for the icm, is to take out all the extra wiring. It's a big loop that runs from to the ecu to the icm, back along the harness to behind the engine, and then to the coil packs. Remove the loop, and go straight to the coil packs

maxiz1
01-03-2016, 09:14 PM
I see your point there. So you left pin no 3 unconnected?

maxiz1
01-06-2016, 12:25 AM
Guys,
I need some help here. The 4 wires (black/blue tracer) i believe supplying 12V to the coil packs. Are each of them specific to a particular coil or can be mixed up? Reason being I'm afraid that after cutting them and if I lose the identification it will be hard to identify them again because they go back all the way to the main harness towards ECU.

koutsa4
01-09-2016, 02:28 AM
Hello and happy new year.i have the same car and i want to delete the ICM and change the coils.Can you please tell me or photo me the wiring freom the icm and the 4 wire from the the coil goes to valve cover?Thank you

Kronprinz
01-09-2016, 08:30 AM
Guys,
I need some help here. The 4 wires (black/blue tracer) i believe supplying 12V to the coil packs. Are each of them specific to a particular coil or can be mixed up? Reason being I'm afraid that after cutting them and if I lose the identification it will be hard to identify them again because they go back all the way to the main harness towards ECU.


Hello and happy new year.i have the same car and i want to delete the ICM and change the coils.Can you please tell me or photo me the wiring freom the icm and the 4 wire from the the coil goes to valve cover?Thank you
I have been looking into this too, the below link seems to be the most straight forward and understanding. Should be a possible sticky
http://www.audizine.com/forum/showthread.php/615999-AEB-ICM-delete-amp-AWP-upgrade-DIY

maxiz1
01-10-2016, 11:15 PM
Thank you very much that was really helpful.

I would like to ask how many wires come out from the main harness into the original coil pack plugs? I believe there are minimum of 8 wires (4 signal + 4 12volts). But I'm not sure whether there are additional wires for the ground going into the main harness. I tried disconnecting the ground lug on the valve cover and there is no continuity between the ground pin and the chassis.

I suspect there are only 8 wires but can somebody please confirm? The reason I'm asking is so that I could buy the appropriate deutsch connector (whether the 8 pin or 12 pin). I want to make the modifications interchangeable for the 2.0t coil packs as well as the original 1.8t ones, so that If I run into trouble I could swap back to the stock setup. This also means that I would need to setup a bypass circuit at the ICM. Thanks.

koutsa4
01-11-2016, 03:21 AM
where do you find the coil adaptor and the pins?

maxiz1
01-11-2016, 04:22 AM
I haven't bought much yet but have ordered the coil plugs from shop.vems.hu

For the main harness plug and pins you can buy from aliexpress or ebay. Search for deutsch connector either the 8 or 12 pin version, which is the question that i'm posting.

For ICM bypass i'm planning to buy some chinese knock off ICM from ebay for 10 bucks and hack the internals.

I haven't decided about the adaptors.

koutsa4
01-11-2016, 06:31 AM
the ICM wiring is 1-2 2-2 4-3 5-4.so i cut those and put them together

- - - Updated - - -

thanks for your help