Audi 2.7T FSI Coil Pack Conversion Kit Installation...

Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

Audi 2.7T FSI Coil Pack Conversion KitInstallation Instructions

ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281 1.800.924.5172 WWW.ECSTUNING.COM 2Table of Contents

AUDI 2.7T FSI COIL PACK CONVERSION KIT INSTALLATION ES#2723130 ES#2730647R

INTRODUCTION

Today we are going to install our ECS Tuning 2.7T FSI Coil Pack Conversion Kit into a B5 Audi S4. It’s no secret that the coil packs and the ignition control modules on the 2.7T are anything but reliable, so this conversion kit eliminates both of those problematic components and utilizes the tried and true 2.0T coil packs. ECS spent countless hours developing this kit so that it is a seamless OE quality fit, and it is extremely easy to install, only requiring a few basic tools. If you don’t have a lot of “wrench time” under your belt, rest assured because we are going to walk you through the installation step by step, and once you’re done you’ll be able to just sit back and admire your work.

The Project:I I I I I I

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I I I I I I I I I I I I I I I I I I I

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2 4

3

Advanced - 3

Pro - 4

2 - Moderate

1 - Easy

Take your time and enjoy the project, it’ll only take you a couple of hours or less. Read these instructions completely first, and with the project overview under your belt, you’ll breeze right through it. Just to make sure you have everything you need, reference the required tool list on Page 5 before you begin. Thank you for looking to ECS Tuning for all your performance and repair needs, we appreciate your business!

ECS Difficulty Gauge

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TABLE OF CONTENTSKit Contents .....................................................................................................................pg.4

Required Tools and Equipment ................................................................................pg.5

Shop Supplies and Materials .....................................................................................pg.6

Installation and Safety Information ........................................................................pg.7

Removing the Original Coils ......................................................................................pg.8

Installing the New Coils & Harnesses .....................................................................pg.10

Modifying the Coil Covers ..........................................................................................pg.14

Schwaben Tools .............................................................................................................pg.15

Symbols:

The following symbols may be used throughout these instructions indicating special attention:

YIELD

FORK IN THE ROAD: When there are different options within any given kit, we will direct you to the proper page and step to continue.

YIELD: Pause for a moment to double check component installation before you continue. Ignoring this can cost you time later during the installation.

STOP: The upcoming steps require specific preparation and/or assistance in the interest of safety. Please read ahead in the instructions and prepare before continuing.

STOP

CAUTION: Pay close attention to these warnings and instructions. Difficult installation, personal injury or component damage may occur if ignored.

TECH TIP: Tips and tricks to make the job go much easier.

NOTE: Additional information that may be useful to the installation depending on your application.NOTE

TECH

TIP





ICM Delete Harness(QTY 2)

2.0T Coil Pack Conversion Harness(QTY 2)

KIT CONTENTS

Allen Head Bolt(QTY 12)

RH Coil Pack Conversion Plate - Anodized Black(QTY 1)

2.0T Ignition Coil - Red(QTY 6)

LH Coil Pack Conversion Plate - Anodized Black(QTY 1)





Note: The tools required for each step will be listed by the step number throughout these instructions.REQUIRED TOOLS

• Protecta-Sockets (for lug nuts) ........................................................ES#2221243• 3/8” Drive Ratchet ....................................................................... ES#2765902• 3/8” Drive Torque Wrench......................................................... ES#2221245• 3/8” Drive Deep and Shallow Sockets ................................... ES#2763772• 3/8” Drive Extensions ................................................................. ES#2804822• Hydraulic Floor Jack ................................................................... ES#240941• Torx Drivers and Sockets ...................................................................ES#11417/8• 1/2” Drive Deep and Shallow Sockets ................................... ES#2839106• 1/2” Drive Ratchet• 1/2” Drive Extensions• 1/2” Drive Torque Wrench ........................................................ ES#2221244• 1/2” Drive Breaker Bar ................................................................ ES#2776653• Bench Mounted Vise• Crows Foot Wrenches• Hook and Pick Tool Set .............................................................. ES#2778980

• 1/4” Drive Ratchet ...............................................................................ES#2823235• 1/4” Drive Deep and Shallow Sockets ................................. ES#2823235• 1/4” Drive Extensions ............................................................... ES#2823235• Plier and Cutter Set ..................................................................... ES#2804496• Flat and Phillips Screwdrivers .......................................................ES#2225921• Jack Stands .............................................................................................ES#2763355• Ball Pein Hammers• Pry Bar Set ...............................................................................................ES#1899378• Electric/Cordless Drill• Wire Strippers/Crimpers• Drill Bits• Punch and Chisel Set• Hex Bit (Allen) Wrenches and Sockets .......................................ES#11420• Thread Repair Tools .............................................................................ES#1306824• Open/Boxed End Wrench Set ..........................................................ES#2765907

Standard Automotive Tools Available On Our WebsiteRequired For This Install









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SHOP SUPPLIES AND MATERIALSStandard Shop Supply Recommendations: We recommend that you have a standard inventory of automotive shop supplies before beginning this or any automotive repair procedure. The following list outlines the basic shop supplies that we like to keep on hand. Shop supplies with a hyperlink are available on our website.

• Hand Cleaner/Degreaser - Click Here• Pig Mats - for protecting your garage floor and work area from spills and stains - Click Here• Spray detailer - for rapid cleaning of anything that comes into contact with your paint such as brake fluid - Click Here• Micro Fiber Towels - for cleaning the paint on your car - Click Here• Latex Gloves - for the extra oily and dirty jobs - Click Here• Medium and High Strength Loctite Thread lock compound - to prevent bolts from backing out - Click Here• Anti-Seize Compound - to prevent seizing, galling, and corrosion of fasteners - Click Here• Aerosol Brake/Parts Cleaner - for cleaning and degreasing parts• Shop Rags - used for wiping hands, tools, and parts• Penetrating oil - for helping to free rusted or stuck bolts and nuts• Mechanics wire - for securing components out of the way• Silicone spray lube - for rubber components such as exhaust hangers• Paint Marker - for marking installation positions or bolts during a torquing sequence• Plastic Wire Ties/Zip Ties - for routing and securing wiring harnesses or vacuum hoses• Electrical tape - for wrapping wiring harnesses or temporary securing of small components



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NEVER get underneath a vehicle that is supported only by a jack, andALWAYS make sure that the vehicle is securely supported on jack stands.

INSTALLATION NOTES

GENERAL PREPARATION AND SAFETY INFORMATION

• RH refers to the passenger side of the vehicle.• LH refers to the driver side of the vehicle.• Always use the proper torque specifications.• If applicable to this installation, torque specifications will be listed throughout the document and at the end as well.• Please read all of these instructions and familiarize yourself with the complete process BEFORE you begin.

• Park your car in a safe, well lit, level area.• Shut the engine off and remove the key from the ignition switch.• Make sure any remote start devices are properly disabled.• ALWAYS wear safety glasses.• Make sure the parking brake is applied until the vehicle is safely lifted and supported.• If using an automotive lift, be sure and utilize the factory specified lift points. Lifting a vehicle in an incorrect location can cause damage to the• suspension/running gear.• When lifting a vehicle using a jack, always utilize the factory specified lift points. Lifting a vehicle in an incorrect location can cause• damage to the suspension/running gear. ALWAYS support the vehicle with jack stands.• Always read and follow all safety information and warnings for the equipment you are using.

ECS Tuning cares about your health and safety. Please read the following safety information. This information pertains to automotive service in general, and while it may not pertain to every job you do, please remember and share these important safety tips.





REMOVING THE ORIGINAL COILSStep 1:

Step 2:

Remove the three screws for the coolant reservoir, disconnect the electrical connector underneath, and move the coolant reservoir to the side (it is not necessary to disconnect any coolant lines). Remove the air box cover, air box duct, and the upper engine covers.

Disconnect and remove the original ignition modules. Loosen the hose clamp on the end of the Mass Air Flow Sensor and disconnect the electrical connector from the sensor. Release the four spring clips holding the air box lid in place, then remove the air box lid and mass air flow sensor together as one piece.

Phillips Head Screwdriver

7mm Socket & Ratchet

COOLANTRESERVOIR

AIR BOXCOVER

AIR BOXDUCT

MASS AIRFLOW SENSOR

UPPER ENGINECOVERS

T-FITTING(FRAGILE)

IGNITIONMODULES

AIR BOX LID

CAUTION: The coolant “T” fitting near the reservoir is very fragile and can break easily. If a replacement is needed, it is available on our website at: ES470541.






Step 3:

Step 4:

Flat Blade Screwdriver

10mm Socket & Ratchet

Loosen both of the coil covers (shown here off the vehicle) by turning the fasteners 1/4 turn counter-clockwise with a flat blade screwdriver. Remove the oil cap and lift up on both covers to remove them.

Remove the bolts holding the original ignition coils to the valve covers. Lift each coil out slightly, release the electrical connector retainer, then discon-nect the electrical connector and remove the coil.

REMOVING THE ORIGINAL COILS





Step 1:

Step 2:

INSTALLING THE NEW COILS & HARNESSES5mm Allen Key - OR - 5mm Allen Socket & Ratchet

Install the LH and RH Coil Pack Conversion Plates onto their corresponding valve cover using the six bolts provided for each plate. Install all six bolts into each Conversion Plate until they are fully seated, then tighten the bolts until they are snug.

Push all six of the new 2.0T Ignition Coils into place until they are fully seated.





Step 3:

Step 4:

Connect the new Coil Pack Conversion Harnesses to the coils, making sure that the connectors are fully seated. You should hear the connector locking tab “click” as it locks into place.

The harness routing is the same for the left and right and is as follows: Each harness will route towards the rear of the engine, make a 90 degree bend, run up the rear edge of the valve cover, make another 90 degree bend and run along the top edge of the valve covers until they connect to the factory wiring harness.

INSTALLING THE NEW COILS & HARNESSES





Step 5:

Step 6: 5mm Allen Key - OR - 5mm Allen Socket & Ratchet

Connect the three harness connectors on each side to the factory coil con-nectors. The three branches of each harness are different lengths, the short-est being the rear and the longest being the front.

Attach the LH and RH harness ground wires. There is an Allen cap screw on each side of the intake “Y” tube that can be used. Attach the ground wire eyelets underneath these screws.






Step 7:

Step 8:

Carefully position the harnesses and connectors so that the engine covers can be reinstalled. Reinstall the coil covers (if used), upper engine covers, the mass air flow sensor, the air box lid, air box duct, and the coolant reservoir.

Install the ICM Delete Harnesses in place of the original ignitionmodules as shown in the picture, then reinstall the air box cover.


IGNITION MODULE ADAPTERS

MASS AIR FLOWSENSOR





Step 1:

Step 2:

If you are reinstalling the coil covers on your car,you will need to cut a clearance notch in each

cover so they will fit over the coil harnesses.

To begin, hold the covers in place and mark the area where the cut out is required.

Cut the notch out of each cover, for this we used a straight air grinder with a carbide bit, however you can use a variety of different tools to cut this notch, depending on the tools that you have.

You can see the notches we cut in our covers by referencing the photos on the right.

MODIFYING THE COIL COVERS

Cut notches here:





At ECS Tuning, we carry a line of high quality Schwaben Tools and Equipment to help you build your ultimate tool collection. Never before has affordability and quality been so closely related. Our entire Schwaben line is subjected to strict in house testing for strength and durability. See what we have to offer and equip your garage without breaking the bank.

SCHWABEN - BUILD THE ULTIMATE TOOL COLLECTION



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Your Coil Pack Conversion Kit Installation is complete!

These instructions are provided as a courtesy by ECS TuningProper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

Although this material has been prepared with the intent to provide reliable information, no warranty (express or implied) is made as to its accuracy or completeness. Neither is any liability assumed for loss or damage resulting from reliance on this material. SPECIFICALLY, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE IMPLIED WITH RESPECT TO THIS MATERIAL. In no event will ECS Tuning, Incorporated or its affiliates be liable for any damages, direct or indirect, consequential or compensatory, arising out of the use of this material.

Audi 2.7T FSI Coil Pack Conversion Kit Installation...

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