This article is intended to be a guide for those of you who want to make your own cop setup. This is a start to finish write-up that covers the materials and tools needed, assembly, wiring, and installation to make your own coil-on-plug setup. Please note, while I used all new parts for my setup which were somewhat costly, this write-up can be followed with used parts and a homemade plate. I just happened to have extra cash in my budget for this project.
Without further delay, here is the write-up.
Tools/ Equipment:
Wire stripper
Wire cutter
Allen wrench set
Wrench/Socket set
Soldering Iron
Electrical Tape
Wire wrap
Rosin core solder
High grade automotive wire
Calipers (optional)
Parts and Prices:
JMFabrications COP plate............................$95.00
300m Coils (4)..........................................$32.5 0 each...............p/n UF269 from rockauto.com (4 required)
Toyota Connectors (4)...............................$6.85 each.................p/n 90980-11246 from Toyota dealership (4 required)
Toyota leads (8)........................................$6.25 each................p/n 82998-12440 from Toyota dealership (8 required)
Hex head hardware (2 packs).....................$1.15 each
Washers........................................... ........$.69
Nuts.............................................. ...........$.89
Coils
Toyota Connectors with leads inserted
Step 1:
Insert two leads into each of the four toyota connectors. Then install one connector on each of the four coils.
Step 2:
After putting the connectors on the coils, I test fitted them in the plate. The JMFab plate is made very well and the coils fit perfectly. The only change I made was that I elongated the holes the leads went through so they would have a little more clearance. Then I put the coils back in and bolted them down with the hardware I purchased.
Step 3:
Since the leads were all black, I put a red line on the top lead from each connector so that I could keep them straight. Then I turned the plate upside down so that I could start wiring it up.
Step 4:
I used the same wiring procedure as described in the other coil on plug threads.
Here is what I did:
First, I soldered the bottom wire from coil 1 to the top wire of coil 4. I had to solder in an extension because the leads were not long enough.
Second, I soldered the bottom wire of coil 2 to the top wire of coil 3.
Step 5:
Next, I soldered the top wires of coil 1 and coil 2 together, and added an extension.
Then, I soldered extensions to the bottom wires from coil 3 and coil 4.
Step 6:
Wrap all solder joints with electrical tape.
Alright guys, you've made it this far. There is not much left to do, but pay close attention to the rest of the wiring. It is crucial. I have a 6 bolt motor in my 2g with a 95 ecu and dsmlink. I am using the invert cas option in dsmlink. However, I wrote this as if I was not using the invert cas option since that applies to the majority. I will explain what to do if you use the invert cas option.
Step 7:
Look at the triangle connector from the stock coil pack and make note of the three wires and which coil they go to.
Coil-on-plug wiring and install with pics-PARTS 1 & 2 combined
