NefMoto

I have the newer 2.0t coils in my car with BRK7ES-11 plugs, and the car ran great for months with them in. Then the other week driving up to school I blew all 4 06H coils. When I pulled them all and they were VERY hot and the bodies had cracked. I noticed the bodies were plastic and online I found they are prone to cracking. So I ordered up some 07K coils and threw those in, same plugs.

They lasted for about a week. The car ran fine for a while, I was able to do multiple 3-4 gear pulls, then all of a sudden when I tried to do another pull, it started misfiring bad at like 5 psi. So I limp to where I need to go and pull the coils. They are also very hot, and show some teal goop coming through the rubber. So I bought 4 new coils from the dealer, and drove the car home. As soon as I got off the exit ramp, I lost a cylinder. Drove it home sounding like a subaru and pulled the coils. Two of them showed the same teal goop, and the other two I could see a crack in the rubber, and they had bulges under the rubber.

So, what could be causing me to blow coilpacks so quickly? I understand the dwell time is different for the 2.0t coils, and it is set too high in the stock 01 tune. Could too high of a dwell time alone cause this problem? Or should I look into replacing my coil pack wiring? I was planning on redoing both dwell time and the wiring, but was wondering if anybody had similar problem and found a solution.

Are you running AL/NLS?

Yes, but I have not used it on the newest coils. I was using LC on the 06H coils, and only NLS on the first set of 07K coils.  The third and most recent set had no exposure to 0ms dwell time.

dwell time if extremely high can cause this.
Sounds like your wiring is screwed though.

dwell time or wiring one or the other.

When you say they had no exposure to 0 dwell do you mean you flashed back a map with ftmon set back to stock 0.5ms or you ran the same map but just didn't NLS/ALS?


What Ecu you running?

Just didn't use NLS/LC. ECU is 4b0906018ch 1.8t.

 I only drove 15 miles on the last set of coils.

So NLS is still mapped in and ftmon still set to 0? Have you tried putting a stock flash back on and seeing if that cures it?

Hi ,

What would be a good FTMON for 2.0 FSI packs ?

I have not. I need to run to the dealer and get 4 new coils. I'm going to do the wiring at the same time as to not throw 100 more dollars down the drain blowing the new coil packs.

FTMON does not need adjusting, look at page 2 of http://nefariousmotorsports.com/forum/index.php?topic=445.15 (http://nefariousmotorsports.com/forum/index.php?topic=445.15) to find out what needs changing for 2.0t coils.

Well I pulled the harness and checked it over. The wiring all seems fine. All power, ground, and signal wires have continuity from the ECU to each connectors, and they all have <1 ohm resistance plug to plug. No power/grounds or signal wires are shorted together. I did make the harness from about 18 inches past the o2 sensor plugs, but all of my splices' heat shrinks are intact, and no wires are worn through.

My next move is to go over the grounds in the car. I am going to re-do the chassis ground near the battery and the small one under the coolant reservoir. I already added a ground directly from the battery to the head using 8ga wire so I'm confident that is grounded.

After grounds are checked, I am flashing a brand new tune, without LC and NLS coded and with maps changed to mimic the MED9 dwell maps. Any other suggestions while I do that stuff?

Been real busy lately so I haven't been able to do much, but the harness is all rewrapped now and mostly installed. I changed the necessary maps in ZUESZ so hopefully I am good to go. I started thinking more into what could've caused it. I bought the first set of 2.0t coils in may 2012. Drove the car the whole summer and never had problems. I have about 11k miles since last January.

I drove the car to school and back home at the end of thanksgiving, before it started to get below ~45F. I noticed a very slight misfire at WOT from time to time but nothing major. The car then sat for 4 weeks due to clutch issues. Got it running dec 23 and drove it back to school when the coils blew jan 6, where the temp was ~10F. The second set went in as cold or colder weather.

Am I wrong in assuming this probably has something to do with the cold?

I highly doubt it has anything to do with the temp. Are the plugs still gapped ok?

Yea plugs are still gapped .040. I'm probably going to pick up some bkr7e1'1s and gap them .035.

You rechecked them when you replaced the coils? Increased gap=increased resistance=increased coil load=decreased service life. Not dramatically so, but worth checking into.

I checked them right before the first set went. I have not measured them since but they looked fine before my most recent set of coils.

So, have you fixed your problem?

I changed the necessary maps for the 2.0 dwell times, and tsrldyn is down 1ms from before. I'm not sure how it behaved on the old flash under load since FTSDRLW was all 3s in my previous file, and I didn't get a chance to log it under load. But on the new maps it stays at 2.6ms all the time, and after applying the KFZDUB factor of ~.875 brings it down to an appropriate 2.275ms.

If I knew the location of szout, it would be much easier. Maybe I'll fire up IDA and start delving into that next.

The wiring looked fine, so I just rewrapped it in high temp waterproof electrical tape, followed by different high temp tape. Cleaned the grounds and it seems to be ok, threw in new BKR7E-11 gapped to .035.  I drove it a bunch, did some 2-3-4 gear pulls and all seems well. I'm going to put more miles on it to be sure.

Today i also blow coil pack.....

situation :
Few day ago - run 7-10times with Flatshift , also AntiLag (15-20times for 1 to max 2 seconds)
Car run great , for about 5days. (i have hitachi coils)

today i ride about 450km , first 400km was fine , but suddenly (i run very slow about 80km/h) , when i press pedal harder i felt misfire. when i stop coil on 2 cylinder was very hot and smell odd. hopefully i have one used 06A  coil  from AUQ.
i drive for about 5km and misfire also come ! also blow fuse.... i replace fuse, and run to home on 3 cylinders...

06a coil was blow , cracked etc and blow fuse, hitachi only misfire - i also found that hitachi has little cracked plastic near the top....
I run on standard pfr6q spark plugs..
boost 1.2b  - 0,7redline from k03.

quite odd that 2 coils was blown on the same cylinder after few minutes one by one... ?  today when i run i didn't used als and nls....

 is possibility that riding on ftmon set 0 cause faillure (without using als/nls) or maybe it was accident ??

This thread makes me glad I went with OEM replacement coils for my s4...

replace 1 coil, but next coil on 3 cyl died.
it has little crack on plastic near top, also 4 cyl hase small crack, but run without misfire , 1 cyl coil hasn't any crack run great.

i plan to buy same bold down coils  Beru (hitachi with beru sticker)

what do you think about 0 dwell time ? when i use als/nls , there is no blowing fuse (i plug smaller fuse 5Amps instead of 10A ) and there is now blowing fuse , so i thing als/nls is quite safe on my setup ? Am i right ?

I set my FTOMN to .5 for the time being. I think my problem was either grounding or wiring. I believe the issues are solved though, I drove two and from the place where they blew before several times without issues.

I recall hearing that the bolt down hitachi coils have a dwell time much to long for the 2.0t coils. You may need to change out your dwell maps if you plan on running 2.0t coils. Otherwise it just sounds like typical coils cracking and failing.

I have 032HJ box (factory work with new style / 2.0T coils) , but i used 032hj with hitachi bolt down coils. i read that is good , because hitachi from fastory ger more dwell time in compare to newstyle/2.0T coils with work on short dwell time.

So if i think right - 032hj + hitachi should be long lasting. i test them, and they stil work on 0,9bar, but 1.2 not. 
I planned to buy beru same like here http://www.034motorsport.com/ignition-solutions-coil-wire-18t-bolt-down-p-476.html
And run 1.2bar boost k03.

I make alse one more test - because i know that i have to buy coils.... so i try to kill them all....

I try to run ALS LC , but there where no changes. No i think that als/nls doesn't kill coils in my case, they probably died due to age (14years) and also 1.2bar boost probably help to kill them + also i run on LPG so the coils are much more stressed (lpg mixture is difficult to fire in compare to pb95).

I would buy Beru hitachi style coils and give some info :)

Check your gap too. Too much gap and the coil has to work harder. I gapped my bkr7e-11s to .035 in.

i have 0.028' gap pfr6q (0.7mm)

update
i run 2 days on 3x hitachi ( one little misfire on above 1bar boost) and also new type coil 1.8T but it was aftermarket VEMO,
today vemo start to mifire badly. probably it was crap shit...  i plug one new type  1.8T ORI VW coil and still 3xhitachi bolt down , and do some test. Tommorow i will get 4 Brand New Bold Down hitachi style BERU coils...

I still thinking about als/nls ? 0 dwell time could blow coils ? i run few times als/nls but without poping fuses , so is this safe for coils or not ?

No, it is not safe to run a non existent dwell.

how about setting dwell time to 0.5 (stock was 6ms) ? what you think about ?
but als probably won't work right ?

next coil blow.... its 3 set...
ftmon 0, als nls used about 15times.
i think spark cut kill coils....

i will flash ecu without als/nls....

with all the issues, I would also flash a stock file and see how the coils react. that's crazy you are killing coils like that when it seems the issue is non existent with other peoples setups. Could you have a bad ground for the coil harness or something? Good Luck!

I should point out, I have flashed my car with FTOMN set to stock, and coils have been fine. But I dont think it was LC/NLS causing the problems, as I was using it for months before the coils initially blew. I redid my harness and grounding at the same time so it's hard to say whats been causing the issues.

hmm... I can't find FTOMN in any of the def files I have for my 1.8t. What is it? Where is it?

catbed- i run on brand new set beru since 20 febuary , and about 2000km on them,  als was used about 15 maybe 25times, but flatshift was used quite often - because it is getting activ  during fast shifts,
also i run on lpg (propan butan) if it is important ?

catbed - what exactly you ground ? valve cover - acumulator ground ? and what else ?

I cleaned my grounds at the battery(chassis ground), at the valve cover, and below the coolant tank.

Minimum dwell time? FTMON or FTOMN or summat

What's the address?  I searched both ways of the letters..I really don't have it.

You are running much to wide a spark plug gap. The only time i ran .040 is when i had 6ms dwell time on my retrofitted ls2 coils for the 1.8t.  I would run .028 or .032 max any more and you will keep killing coils.

I run  on 0.028  gap with pfr6q spark plugs, with ALS/NLS and i think als/nls kill coils.... yesterday next plug start to die... it comes from set which was working 2 months with als/nls, but from about 1 week i run without als/nls (coded out from bin) and i think that these coils were expose on dwell time =0 on als/nls and thats the problem which kill coils.. or maybe my als//nls code is wrong ?

I know this is an old post but, I have been playing with a file on my girlfriends car. (2003 A4 318AK ecu) 10 days ago I threw in a set of 42lb injectors and changed the nef stg 1 tune for the injectors and AL/NLS. Then the next day I threw in a k04 and cat delete down pipe and worked on tunes till 7 days ago. 3 days ago she went on a longer drive (AL/NLS have not been tested since very first file) and it started to miss bad, coils were split(2L FSI coils). A friend came and brought her another set and it cooked them on the way home. When she got home we put stock coils in and a file disabling the AL/NLS even though it had not been used. The car ran fine in the driveway that night. The next morning on the way to take the kid to school it killed them, blew one right in half. Last night I put another set of stock coils in and let it idle for 10 min and the were smoking hot. Today I put my O scope on the coil trigger wire 10.8 MS. I decided to take a fresh file and put the new maps into it and delete the cat and re flash. Now it idles at 2.76ms, seems to be fine. I also never had the FTOMN less than .3. It never built boost either when originally tested. I think it had something to do with the code itself.

Coils cannot get hot from NLS code, hot coils are overcharging. As you measured, 10ms is about 2x the maximum charging time the tfsi coils want to see. The nls code only sets 0ms at the coil dwell time when conditions are met.

This information is incorrect. In some ECU's there is a bug/feature in the ignition coil driver. If you set the charge time to 0ms, it actually sets infinite charge time instead.

when was trying to figure out the code in the past and add some other features i accidentally replaced a registrar with another...although everything was working fine i had to replace my coild every 50 to 60km because they were getting hot and eventually die..well it didn`t took me long to compare it with the initial code and find my mistake but things can happen.

the 29f400 ecus can blow coils or even fuses too if set at 0.0

Okay, lets say I worded myself incorrectly. 0ms dwell cannot kill coils but ftomn 00 in a 512kb ecu will kill coils or blow fuses. I have used 01 ftomn in all my 512kb ecus, but I was more referring to this guys post who has a 2003 AK ecu. In his case, TSMX should be set to something more appropriate at least...but better to put new values in kftsrl

Or did you happen to accidentally have some value like 6A in ftomn? Because that is a minimum coil dwell of 10.6
The lc nls code is very simple, all it does is zero tsrldyn ,if conditions are met, which then passes through ftomn afterwards. So basically the code could not cause the problem, only ftomn.