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.!

  3. whealmn
    March 11th, 2012 at 20:19 | #3

    my jeep is kicking and bucking like crazy, i replaced the coil and it ran good for about 15 minutes on a hot sunny day and then the problem reappeared. i see small sparks dancing around the outside of the coil at night. do you know if silicone sealant would also work to seal a coil? its running very rich with black smoke. thanks, whealmn

  4. March 11th, 2012 at 23:08 | #4

    Any non-conductive coating will probably work, BUT it also needs to handle the extreme temperature from the engine. That’s why I used JB weld because it can handle extreme temps and is non-conductive.

  5. greg
    June 13th, 2012 at 22:47 | #5

    Thanks for this video. And I do apologized for the late post here. I encountered some problems with my ignition coil and I want to fix this problem and at the same time, to save money thats why I searched for some solutions here at the internet and I saw this one.

  6. December 27th, 2012 at 13:46 | #6

    I stumbled on this article while also searching for a cheaper solution than buying a new OEM ignition coil. I will be trying this tonight to see if it fixes my problem. Right now my car runs rough and misfires while accelerating. The more moist it is outside the worse the problem is. After about 15-20 minutes of the engine being on the problem dissipates and the car goes back to being a beastly strong runner. So i assume the moisture is baked out of the coil by the heat of the engine.

    I have a 2003 Jetta 2.0 GLS by the way. I will post back in the forums once I try this and let everyone who also may happen to stumble on this know how it worked out.

    Note: I will be running the car prior to applying the fix as to make sure all of the moisture is out before I seal the coil up.

    PS: If anyone needs affordable web design I do freelance work. Also giving anyone $50-$100 per referral they send me. Thanks guys. I’ll post back tomorrow with the results.

  7. Frezo
    January 4th, 2013 at 03:14 | #7

    I have a audi a4 1998 1.8 with coil pack cracks. I have sealed the cracks with eproxy and it is still misfiring. Is this a sign that the pack has just gone bad?

  8. June 23rd, 2013 at 02:17 | #8

    Hi guys, I had the same issues for a long time with my 2000 VR6 Jetta. I replaced the coil pack and plugs and it seems to be working now. I was able to get a new coil pack off of eBay for only $45 though. If the epoxy doesn’t work for you… http://www.ebay.com/itm/321019494291?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

  9. sam
    May 20th, 2016 at 10:25 | #9

    hi guys l ran my engine without coolant and it over shoot the temp and stopped then the coil started to not to fire is there a link btwn the Problems…n wats tht

  10. Eric
    July 17th, 2016 at 21:37 | #10

    Dear Sir or Madam,

    Thank you very much for reading my email. We are the manufacturer of ignition coil for Chevrolet Corvette.
    Based on Tianjin University Internal Combustion Engine Research Institute,we have specialized in ignition coils for more than ten years with lots of customers in the world. Good quality and competitive price are the foundation of our success.
    Should you have any questions, please don’t hesitate to contact me. FREE SAMPLES will be provided for your evaluation!

    Best Regards,
    Eric

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