Chasing misfires, repair or replace ignition coil connector and wiring

[Ducati899]

Hi,

Has anyone repaired or replaced the ignition coil connector or wiring? Mine are so jacked and I have to do something about it but can't seem to find replacement pigtail, or Audi pin connectors so I can run new wire into the connector.

Is there a vendor that sells a replacement pigtail? Should I try to source the audi pin removal tool, connectors so that I can remove damaged wiring near the connector?
Any help appreciated.

Best

[SideMirror]

https://www.ebay.com/itm/30413513034...mis&media=COPY

https://www.ebay.com/itm/33398903739...mis&media=COPY


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[Ducati899]

https://www.ebay.com/itm/30413513034...mis&media=COPY

https://www.ebay.com/itm/33398903739...mis&media=COPY


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Thanks gjweyman.

However, those are 4-pin connectors and the ones I'm looking for are 3-pin like this used one on ebay https://www.ebay.com/itm/284172704629.
Was trying to figure out if I can remove the pin and damaged wires on these connectors and reuse my connectors.

[SideMirror]

https://www.prowireusa.com/txl-wire

If you decide to make up your own, recommend it. You need materials such as Tesa tape, TXL wire, DR25 heat shield, maybe techflex PET sleeving to cover the loom wires, and soldering wires vs butt connectors are less bulky.

https://www.mcmaster.com/ Has most or all of what's needed too... Look for the wiring diagram

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[SideMirror]

Ok sorry thinking about going to a newer 4-pin coil pack to delete ICM.

Depin tool https://www.ecstuning.com/b-schwaben...caAq_VEALw_wcB

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[SideMirror]

The pins may be found here.

https://www.te.com/usa-en/products/t...s-splices.html

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[Ducati899]

Thank you for taking the time for this info. I really appreciate it. I'm on a mission to replace/repair all the damaged wiring in the engine compartment but want to do it the correct way, or smart way.
I am also thinking about doing the 2.0 coil swap from ECS which might solve having to rewire these older connectors I hope.

https://www.ecstuning.com/b-ecs-part...s/002686ecskt/

[S4James]

Or you could save yourself time and money https://jaeinnovations.com/products/...wiring-harness also sold on the ETSpec site https://etspec.com/b5-s4-coil-wiring-replacement-kit

I havnt put mine in yet, but i can attest that its well made.

then get yourself 6 35usd "rs6" boltdown coilpacks from whoever and complete the kit. skips all the conversion nonsense, failure prone connectors, old wiring etc.

[Silverex]

and soldering wires vs butt connectors are less bulky.

Do NOT solder. Use uninsulated closed or open barrel splices with adhesive lines shrink wrap over. Done right and they arnt bulky.

I also make coil harnesses with all OEM connectors, Tefzel wire, DR25 sheathing, and a DT connector. Replaces everything from coil to ECU. If interested drop me a DM.

Here’s pics of some I’ve made.





**edit**

Depin tool https://www.ecstuning.com/b-schwaben...caAq_VEALw_wcB

I highly suggest buying that tool kit no matter what. The pin removal tools work awesome and the connector removal tool helps prevent breaking the tabs.

[Ducati899]

Or you could save yourself time and money https://jaeinnovations.com/products/...wiring-harness also sold on the ETSpec site https://etspec.com/b5-s4-coil-wiring-replacement-kit

I havnt put mine in yet, but i can attest that its well made.

then get yourself 6 35usd "rs6" boltdown coilpacks from whoever and complete the kit. skips all the conversion nonsense, failure prone connectors, old wiring etc.

I saw that harness and was reading on the installation which seems fairly straightforward. Is it possible to still delete ICMs if I install this harness or that system stays?

Thanks

[TwoSnelz]

Or you could save yourself time and money.....

....


...then get yourself 6 35usd "rs6" boltdown coilpacks from whoever and complete the kit. skips all the conversion nonsense, failure prone connectors, old wiring etc.

Highly recommend avoiding the push down coilpacks and stick with the bolt downs like James suggested.

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[Ducati899]

DM sent

[Ducati899]

Highly recommend avoiding the push down coilpacks and stick with the bolt downs like James suggested.

Sent from my SM-G973U using Audizine Forum mobile app

10/4 on that. Thank you!

[Ducati899]

more questions as I delve into this engine's wiring.
This single wire/pin connector is in bad shape. It's mounted below the DV on the driver side IM corner. The wiring is exposed all the way into the connector. How would you go about repair/replacing this?

[S4James]

repin with a new terminal.. you can get the premade wires with a terminal crimped on each end from ECS you the cut back some of the offending wire, and using a barel crimp lay in your new section, and insert into the connector.

[S4James]

I saw that harness and was reading on the installation which seems fairly straightforward. Is it possible to still delete ICMs if I install this harness or that system stays?

Thanks

ICMs are eliminated.

[Ducati899]

repin with a new terminal.. you can get the premade wires with a terminal crimped on each end from ECS you the cut back some of the offending wire, and using a barel crimp lay in your new section, and insert into the connector.

Yes, makes sense. Thank you.

[RMode]

Fwiw, push down coils (genuine audi, not any rebranded aftermarket) on my car for the last 50k miles (3 years). Zero issues of any kind.


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[CELison]

Zero issues here as well.

[Ducati899]

Fwiw, push down coils (genuine audi, not any rebranded aftermarket) on my car for the last 50k miles (3 years). Zero issues of any kind.


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Thank, appreciate that feedback.

- - - Updated - - -

Zero issues here as well.

Thank you too.

[S4James]

My pushdowns were great until the connectors melted.. Thats a fault with the materials used in the early conversion kits not the coils... Id rather put the bolt down coils for aesthetic reasons more than anything.

[Ducati899]

Hi AZ B5 S4 family,

Reporting back to everyone on this thread who responded.

Thank you for helping me sort out misfires my car was experiencing. Yesterday after finally completing all the coil wire and sensor repair/replacements, the car finally has ZERO FAULTS. Had a scare/disappointment on initial startup, VAG started reporting MAF errors, lol. But I saw that I had forgotten one of the clamps on the hose.

List of repairs
Basically repaired/replaced all the coil connector wires coming out of the harness. (probably the original cause of the misfires)
New N75 sensor.
New brake pump vacuum hose.
Replaced torn/or old vacuum hoses.
Cleaned the MAF.

Drove the car about 10 miles and definitely is a huge improvement. I feel some slight stuttering at 3K when WOT but engine pulls very strongly when driven normal and it seemed to improve as I drove the car more.


Thanks to SILVEREX for building some pigtails and sending out with connectors.
Thanks to S4James for the links.
Thanks to SideMirror for the links.

I feel much more confident working with wiring now!

Going to take a short break on engine stuff and focus on restoring the paint job and and wheel touchup.

THANK YOU AZ B5 PEOPLE