Ignition Coil Pack Repair

My 1998 VW Golf GTI VR6 is a great car, but it does have 1 nagging problem.
The ignition coil pack.

Initially, it took me a couple years to discover the cause of my engine’s hesitation and misfire codes.
When the first coil pack failed catastrophically, the spark plugs stopped firing and
sent excess fuel down the exhaust and melted my catalytic converter.
I have replaced my coil pack 4 times now because none of the brands are reliable.

Over time, the plastic housing of the coil pack begins to crack.
The hairline cracks allow sparks to jump to ground through the housing
instead of going to the spark plugs resulting in random misfires.
The problem is multiplied whenever there is extra moisture on the coilpack, like the morning dew.

The coil pack for my VR6 costs around $200-$300.
Rather than buying a 5th coil and waiting for it to crack…
I decided to repair my cracked one.

This technique has been covered before on many websites and forums.
Basically, you apply a 2 part epoxy over the cracks OR the entire plastic housing.
The epoxy is non-conductive and insulates the cracks.
My coil was very dirty, so I disassembled and washed it so the epoxy would stick.

Here is a 2 minute video of my repair.

Comments

  1. James
    November 14th, 2009 at 17:05 | #1

    Excellent video. Recently self-diagnosed a faulty coilpack in my 2000 Jetta GLX after terrible performance and misfires in humid weather and searching through forums. Was about to buy one off eBay for about $180 (after calling VW dealership and getting approx $800 estimate) and then found your video. Am looking forward to doing this on my next day off. Thank you for taking the time to record this repair and upload it to benefit others… I know many people have this problem which is pretty ridiculous, so thanks for doing this.

  2. paul
    August 6th, 2011 at 22:24 | #2

    hey thanks for the info. I have the exact same car. In the morning starts up and sounds great. Problem is it dies at idle after about 10 min of running, then wont start til cool. no spark at that point. I know one of the vacuum hoses needs to be reattached (the Secondary AIR one under the manifold). Getting {random misfire” error codes and Cam Position Sensor out of sequence msg also. replaced this sensor.

    any help and ideas is greatly appreciated.!

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