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    2004 Volvo V70R AWD 2.5L Turbo DOHC 5cyl

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    VW Passat & Audi A4 1990-2000

    Ignition Coil Pack

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    TESTING

    WARNING
    Testing the ignition system components requires the use of a high impedance digital volt/ohm meter (DVOM) and an LED test light such as Tool No. VAG 1527. A standard analog voltmeter or a standard incandescent 12-volt test light will cause damage to the system's components.

    Voltage Supply Check
    1.8L engine
    1. Check battery voltage and if discharged, charge as necessary.
    2.  
    3. Verify the fuse for the ignition coils is OK and has power when the ignition key is turned on.
    4.  
    5. Disconnect the 4-pin electrical connector from the power output stage of the ignition coil.
    6.  
    7. Turn the ignition switch on.
    8.  
    9. Using a suitable LED test light, such as VAG 1527B, or its equivalent, check for power between ground and each of the 4 electrical terminals. The light should light for each of the 4 terminals.
    10.  
    11. If the light does not light for each of the terminals, check the wiring and repair as necessary.
    12.  



    Click image to see an enlarged view

    Fig. Terminal position location for terminals 1-2-3-4



    Click image to see an enlarged view

    Fig. The 4-pin power output stage electrical connector is shown disconnected. An LED test light is used to check for power between each terminal and ground

    2.8L vr6 engine

    This test confirms the coil is receiving a voltage signal to charge the coils.

    1. Remove the ignition coil trim cover.
    2.  
    3. Measure the battery voltage. If discharged, charge as necessary.
    4.  
    5. Remove the 5-pin harness connector from the ignition coil pack.
    6.  
    7. Using a suitable digital voltmeter, carefully connect the test probes to the outer most connector terminals. With the two connector guide slots on the bottom the left most terminal is the negative terminal (terminal 1) and the right most the positive lead (terminal 5).
    8.  
    9. Turn the ignition switch ON , but Do NOT start the engine.
    10.  
    11. The voltmeter should read 10-12 volts.
    12.  
    13. If the voltmeter does not read 10-12 volts, check the integrity of the wiring, and supply voltage to the ECM.
    14.  
    15. Turn the ignition switch OFF and plug the 5-pin harness connector into the coil pack.
    16.  



    Click image to see an enlarged view

    Fig. On VR6 engines, the coil's 5-pin electrical connector is located under the coil trim panel



    Click image to see an enlarged view

    Fig. Terminal position location for terminals 1 - 2 - 3 - 4 - 5

    2.8L V6 (AFC) engine
    1. Check battery voltage and if discharged, charge as necessary.
    2.  
    3. Verify the fuse for the ignition coils is OK and has power when the ignition key is turned on.
    4.  
    5. Disconnect the 3-pin electrical connector from the power output stage of the ignition coil.
    6.  
    7. Turn the ignition switch on.
    8.  
    9. Using a suitable digital voltmeter, check for battery power between ground and each of the 3 electrical terminals. Battery voltage should be present for each of the 3 terminals.
    10.  
    11. If battery voltage is not present for each of the terminals, check the wiring and repair as necessary.
    12.  



    Click image to see an enlarged view

    Fig. Terminal position location for terminals 1 - 2 - 3

    2.8L V6 5 Valve (AHA) engine
    1. Check battery voltage and if discharged, charge as necessary.
    2.  
    3. Verify the fuse for the ignition coils is OK and has power when the ignition key is turned on.
    4.  
    5. Disconnect the 5-pin electrical connector from the power output stage of the ignition coil pack
    6.  
    7. Turn the ignition switch on.
    8.  
    9. Using a suitable digital voltmeter, check for battery power between terminal 1 ( + ) and terminal 2 ( - ). The measured voltage should be 11.5 volts or greater.
    10.  
    11. If the voltage is below 11.5 volts check the wiring and repair as necessary.
    12.  



    Click image to see an enlarged view

    Fig. 2.8L V6 5-valve (AHA) coil pack terminal position location for terminals 1 - 2 - 3 - 4 - 5

    Signal Check

    This test confirms that the ECM is sending an activation signal to the coils or coil pack for firing the spark plugs.


    WARNING
    This test requires the use of an LED test light. Do NOT use an incandescent test light; the current required to illuminate the lamp will damage the Engine Control Module (ECM).

    1.8L engine
    1. Remove the fuel pump fuse to prevent the cylinders from filling with fuel while the engine is being cranked.
    2.  
    3. Disconnect the 5-pin electrical connector from the power output stage.
    4.  
    5. Position the removed connector such that the wire release bracket is facing up, as the electrical connectors are visible.
    6.  
    7. Connect the LED test light to a good ground and to the left most electrical terminal (No. 1 ) and crank the engine. The LED test light should flash.
    8.  
    9. Repeat the same test on terminal 2 (the next terminal to the right). The LED test light should flash when the engine is cranked.
    10.  
    11. Repeat the test for terminals 4 and 5 . Do NOT test at terminal 3 (center terminal).
    12.  
    13. The LED light should flash when the engine is cranked while the test light is connected to ground and any of the following terminals: 1 , 2 , 4 or 5 .
    14.  
    15. If the LED does not flash, this indicates that a signal is not being sent to the coil. Causes include faulty wiring, or problems with the Crankshaft Position (CKP) Sensor and/or Engine Control Module (ECM). For additional information, please refer to the following topic(s): Driveability and Emission Controls, Crankshaft Position Sensor, Engine Control Module.
    16.  
    17. Turn the ignition switch OFF and plug the harness electrical connector.
    18.  
    19. Install the fuel pump fuse.
    20.  

    2.8L vr6 engine
    1. Remove the fuel pump fuse to prevent the cylinders from filling with fuel while the engine is being cranked.
    2.  
    3. Remove the 5-pin harness connector from the ignition coil pack.
    4.  
    5. Using an LED test light, connect the leads to terminal 2 and terminal 5 .
    6.  
    7. Turn the ignition switch ON and crank the engine.
    8.  
    9. While the engine is cranking, the LED test light should flash. This indicates that a signal is being sent to the power stage inside the coil.
    10.  
    11. Turn the ignition switch OFF and reconnect the test leads to terminals 3 and 5 .
    12.  
    13. Again, turn the ignition switch ON crank the engine. Verify that the LED flashes.
    14.  
    15. Turn the ignition switch OFF and reconnect the test leads to terminals 4 and 5 .
    16.  
    17. Crank the engine with the ignition switch once again, and verify that the LED flashes.
    18.  
    19. If the LED does not flash, this indicates that a signal is not being sent to the coil. Causes include faulty wiring, or problems with the Crankshaft Position (CKP) Sensor and/or Engine Control Module (ECM). For additional information, please refer to the following topic(s): Driveability and Emission Controls, Crankshaft Position Sensor, Engine Control Module.
    20.  
    21. Turn the ignition switch OFF and plug the harness electrical connector.
    22.  
    23. Install the fuel pump fuse.
    24.  

    2.8L V6 (AFC) engine
    1. On 2.8L V6 (AFC) engines:
    2.  
    3. Remove the fuel pump fuse to prevent the cylinders from filling with fuel while the engine is being
    4.  
    5. Disconnect the 4-pin electrical connector from the power output stage.
    6.  
    7. Position the removed connector such that the wire release bracket is facing up, as the electrical connectors are visible.
    8.  
    9. Connect the LED test light to a good ground and to the terminal 1 and crank the engine. The LED test light should flash.
    10.  
    11. Repeat the same test on terminal 2 (the next terminal to the right). The LED test light should flash when the engine is cranked.
    12.  
    13. Repeat the test for terminals 3 and 4 . The LED light should flash when the engine is cranked while connected to ground and any of the terminals.
    14.  
    15. If the LED does not flash, this indicates that a signal is not being sent to the coil. Causes include faulty wiring, or problems with the Crankshaft Position (CKP) Sensor and/or Engine Control Module (ECM). For additional information, please refer to the following topic(s): Driveability and Emission Controls, Crankshaft Position Sensor, Engine Control Module.
    16.  
    17. Turn the ignition switch OFF and plug the harness electrical connector.
    18.  
    19. Install the fuel pump fuse.
    20.  

    2.8L V6 5 Valve (AHA) engine
    1. Remove the fuel pump fuse to prevent the cylinders from filling with fuel while the engine is being cranked.
    2.  
    3. Disconnect the 5-pin electrical connector from the power output stage.
    4.  
    5. Connect the VAG 1527B LED test light or its equivalent to terminal 2 and 3 (the next terminal to the right) and crank the engine. The LED test light should flash.
    6.  
    7. Repeat the same test with the LED test light connected to terminals 2 and 4 . The LED test light should flash when the engine is cranked.
    8.  
    9. Repeat the same test with the LED test light connected to terminals 2 and 5 . The LED test light should flash when the engine is cranked.
    10.  
    11. If the LED does not flash, this indicates that a signal is not being sent to the coil. Causes include faulty wiring, or problems with the Crankshaft Position (CKP) Sensor and/or Engine Control Module (ECM). For additional information, please refer to the following topic(s): Driveability and Emission Controls, Crankshaft Position Sensor, Engine Control Module.
    12.  
    13. Turn the ignition switch OFF and plug the harness electrical connector.
    14.  
    15. Install the fuel pump fuse.
    16.  

    Resistance Check

    The secondary resistance of the coil packs on the 2.8L V6 engines can be checked. Because of their internal circuitry, the 1.8L and VR6 coils cannot be checked using conventional test equipment.

    2.8L V6 (AFC) engine
    1. Make sure the ignition is in the OFF position.
    2.  
    3. Disconnect the spark plug wires from the ignition coil pack.
    4.  
    5. Using a suitable digital ohmmeter, measure the resistance for the coil pack between the opposing plug wire connections for each of the coil's paired connections.
    6.  
    7. If the resistance is between 9,000-14,000 ohms, the secondary circuit of the coil is OK.
    8.  



    Click image to see an enlarged view

    Fig. The secondary resistance is measured between the opposing plug wire connections

    2.8L V6 5 Valve (AHA) engine
    1. Make sure the ignition is in the OFF position.
    2.  
    3. Disconnect the spark plug connectors from the spark plugs.
    4.  
    5. Using a suitable digital ohmmeter, measure the resistance at the spark plug connectors between the opposing connections for each of the paired ignition coils.
    6.  
    7. The combined resistance should be 18,000-25,000 ohms.
    8.  
    9. Next, remove the ignition cables from the coils and check the resistance of each of the six cable and connector combinations.
    10.  
    11. The resistance should be 4,000-6,000 ohms.
    12.  
    13. Measure the resistance for the coil pack between the opposing plug wire connections for each of the coil's paired connections.
    14.  
    15. The resistance should be between 8,000-14,000 ohms for the secondary circuit of the coil.
    16.  
    17. If the resistance is within specification for the measured component, the secondary circuit of the coil and wire assemblies are okay.
    18.  



    Click image to see an enlarged view

    Fig. The secondary resistance is first checked between the opposing spark plug connectors, then the wires are removed to check the coil pack resistance

    REMOVAL & INSTALLATION
    1. Make sure the ignition is in the OFF position.
    2.  
    3. Note the radio code and disconnect the battery.
    4.  
    5. If necessary remove the trim panel covering the ignition coils or coil pack assembly.
    6.  
    7. Remove the harness connector(s) from the ignition coil pack or ignition coil assembly.
    8.  
    9. Using a paint marker or other means, mark each wire or connector so they can be installed in their proper locations upon installation.
    10.  
    11. On vehicles equipped with coil packs, disconnect the spark plug wires. When removing the wires, make sure to pull on the boots, not the wires themselves, as they may be damaged.
    12.  
    13. Remove the fasteners that secure the coil pack or ignition coil to the cylinder head. On models with coil packs, make sure to hold the coil pack when removing the fasteners.
    14.  

    To install:

    1. On vehicles equipped with coil packs, clean the dielectric grease from the coil pack mounting surface on the cylinder head. If reinstalling the original coil pack, make sure to clean the grease from the coil pack as well.
    2.  
    3. Apply an even coat of dielectric grease to the coil pack mounting surface on the cylinder head.
    4.  
    5. Position the coil pack, and insert the mounting bolts. Finger-tighten the bolts to hold the coil pack in place.
    6.  
    7. Tighten the fasteners to 88 inch lbs. (10 Nm).
    8.  
    9. On models with coil packs, place a small amount of dielectric grease on each spark plug wire terminal, and install the spark plug boots in the proper order. If a new coil pack is being is installed, note the marks on the old coil pack, using them as a guide to install the spark plug wires on the new coil pack.
    10.  
    11. Plug in the electrical harness connector(s) to the ignition coil pack or ignition coil(s).
    12.  

     
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