D2 Coil packs

P38

Well-known member
Mar 8, 2014
157
3
Michigan USA
I'm refitting everything after a head gasket job on a 2000 Bosch engined D2. Try as I might I can't get the coil pack to sit in the right place so I can screw it onto the manifold flange. It seems too high (the bracket fouls just below the weather strip) and the plug lead caps are hard against the air-con pipes.

Anyone any ideas? Ot are they all THAT tight a fit?
 

BackInA88

Well-known member
Dec 6, 2007
392
1
Troy, Michigan
The only way my coil pack can go in is with all the plug wires removed and I have to snake it in on an angle from the passenger side.
 

discostew

Well-known member
Sep 14, 2010
7,735
1,026
Northern Illinois
I take my long pry bar and lay the handle end against the pipes and hit the blade end with a hammer. Moves them back just enough for that shit to slide into place.
 
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Rockbeard

Well-known member
Jul 18, 2015
80
0
memphis, tn
when i do head jobs on these, i wire up the coils first, install them while only the lower intake plenum is bolted on. here's the thing - there are 4 screws that hold the coils on. 2 in the back (lower manifold) and 2 toward the front which are just a little higher (attaching to the upper intake manifold. so while you can see everything, mount the coil packs with plug wires installed properly, but only install the back 2 screws, and leave them loose. just catch a few threads if you read me. the other 2 screws fasten the packs to the uppper manifold which obviously isn't on yet. you leave the back screws loose so you can tilt the coil assembly back so you can install the upper plenum. granted, it's no walk in the park, but you can run in the last two screws if you can kneel or belly flop on top of the engine and peer down and you can barely see the holes. it's 1/4 inch extension time with maybe a magnetic socket. i find this the worst part of the whole job, but once you get the hang of it, you get wiser.
 

Maximumwarp

Well-known member
Mar 22, 2015
836
26
Fairburn GA
when i do head jobs on these, i wire up the coils first, install them while only the lower intake plenum is bolted on. here's the thing - there are 4 screws that hold the coils on. 2 in the back (lower manifold) and 2 toward the front which are just a little higher (attaching to the upper intake manifold. so while you can see everything, mount the coil packs with plug wires installed properly, but only install the back 2 screws, and leave them loose. just catch a few threads if you read me. the other 2 screws fasten the packs to the uppper manifold which obviously isn't on yet. you leave the back screws loose so you can tilt the coil assembly back so you can install the upper plenum. granted, it's no walk in the park, but you can run in the last two screws if you can kneel or belly flop on top of the engine and peer down and you can barely see the holes. it's 1/4 inch extension time with maybe a magnetic socket. i find this the worst part of the whole job, but once you get the hang of it, you get wiser.

This is exactly what I did. A little fiddly with thick fingers, but it wasn't too bad.
 

listerdiesel

Well-known member
When fitting the coil pack bolts, pack the bolt heads tightly into the socket with a piece of paper or polythene. If you use a long 1/4" extension you can get at all of them, but remember to cover the intake holes with duct tape BEFORE you do anything, those intakes are like a magnet for sockets and small screws.

I dropped a coil pack screw down one of mine, the screw ended up resting against a partly open valve head and I got it out with a magnet.

Peter