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.