1.6 MPI - Spark Plugs, Leads, Coil Pack (& Air Intake Seals) DIY

1 год назад

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Complete ignition replacement on 1.6 MPI (BSE) engines found in Audi A3, Seat Altea, Cordoba, Ibiza, Leon and Toledo; Volkswagen Caddy, Golf, Jetta, Passat, Polo and Touran and Skoda Octavia 2.

NOTE: For spark plugs and coil pack it is not strictly necessary to remove the air intake.

My problems were:
- Sometimes at full throttle the check engine light would come on with the ASR light off, the check engine light would go out after a few seconds.
- The error codes in the ECU were all misfire codes (P0300, P0301, P0302) and once I got P1212 (cylinder shutdown bank 1).
- After restarting the engine, the ASR OFF also disappears.
- The colder it was outside, the worse the problem and vice versa.

Since I did't feel like investigating much, I decided to just replace the whole ignition, as going one by one (spark plugs, leads, ignition module) is pretty painful with the intake in the way.

Turns out the spark plugs were shot and there was corrosion on both the leads and the ignition module terminals on the cylinders that were misfiring. So the problems were compounded. After replacing the ignition, the engine ran better than it had in years. Not only did the big problems go away, the engine just feels much more responsive at lower revs and is quieter too.

Tools required:
- Just basic hand tools with 16mm spark plug socket
- Only speciality was XZN M8 socket ("triple square", commonly confused with TORX), see https://www.amazon.de/s?k=xzn+m8

Parts used:
- Ignition module HITACHI 138425 (Made in Germany)
- Ignition cables BorgWarner (BERU) ZEF1224 (Made in France)
- Spark plugs: DENSO IK20TT (Made in Japan) - you don't need to get expensive Iridium one, though
- Elring and Gates seals for the air intake

Total just under 160 EUR

Timestamps:
0:00 Intro
0:06 Disconnect battery
0:11 Disconnect secondary air pump
1:08 Remove air intake
2:39 Replacing the ignition module
3:33 Carbon cleaning
3:42 Removing old wires
3:54 Replacing spark plugs
4:24 Replacing the air intake seals
4:58 Fitting new leads
5:39 Reassembling the air intake
6:20 Reassembling the air pump
6:46 Final touches and test run
7:39 My problems and has this solved them?
7:45 Costs (time and money)
7:50 Air intake seals old & new
8:08 Ignition module old & new (and corrosion on old)
8:31 Spark plugs old & new (and wear on the old)
8:53 Pipes old and new (and corrosion on the old)
9:29 Dirt on the air intake (first time off)

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