Sphenic Technologies Inc. SPDi Spark User manual

SPDi Plasma Ignition
Installation Manual
V o l k s w a g e n 1 . 8 T P a g e | 1/4
Engine: Volkswagen/ Audi 1.8 Turbo
Safety Instructions: (Please read and understand these safety instructions thoroughly prior to use)
1. This kit is designed to be installed on the Volkswagen 1.8T engine. SPDi kits are available for other engine types.
2. This kit should be installed by a knowledgeable, professional mechanic.
3. Prior to beginning installation, ensure that your vehicle is situated in a safe manner: a) place vehicle on a flat level
surface; b) turn the engine off and allow it to cool; c) remove the ignition key; d) automatic transmissions should be
placed in park, e) manual transmissions should be placed in gear or in neutral with the emergency brake engaged
4. It is recommended, but not essential, that the negative battery cable is disconnected during installation. Please consult
the vehicle owner's manual to determine if there are any issues related to the alarm system or vehicle computer systems
prior to disconnecting the battery.
5. SPDi should only be installed on engines in good operating condition. Engine defects should be corrected (repaired) prior
to SPDi installation. Check engine lights should be investigated and corrected.
6. Hazard: The SPDi module does not contain any user replaceable parts. Do not attempt to open, dismantle or modify the
SPDi module for any reason. An electrical shock risk exists even when the unit is not powered.
Notes:
1. Spark Plugs: It is highly recommended that new Spark Plugs are installed with SPDi.
2. Custom Tunes: Custom tuned engines will benefit from adjusting the air/fuel mixture and ignition timing to complement
SPDi technology.
3. Defects: If any defects are discovered with the SPDi system, immediately discontinue use and contact your SPDi dealer.
Parts Included:
1. SPDi Ignition Unit
2. SPDi Unit Mount
3. Power Relay
4. ECU Interface Harness
5. SPDi Ignition Coil x 4
6. Ignition Wire Harness
7. M4 Bolt 20mm & Nut x 2
8. Zip Ties x 4
9. M6 bolt 20mm x 10
10. M6 Nut x 2
11. M6 Washer x 2
12. Quick Splice
Connector x 5
Tools Required:
8 & 10mm socket
8 & 10mm wrench
Spark Plug Socket
Torque Wrench
Electric Drill
7/64” Drill Bit
Utility Knife
Pliers

SPDi Plasma Ignition
Installation Manual
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Installation Procedure:
1. Remove battery cover and disconnect negative(-
) battery terminal at the beginning of the
installation.
2. Remove the top engine cover [4 bolts] to expose
the ignition coils.
3. Disconnect and remove the stock ignition coils,
as illustrated below.
4. Remove the stock spark plugs and replace with new
plugs. [NGK PFR6Q recommended]
Gap to 0.023" [0.6mm] and reinstall. Torque the plugs
to stock specifications 22ft-lb [30N·m]
5. Install SPDi coils aligning the coil plug connector as
illustrated. Install the coil hold down bolts, if the stock
coils did not include these use the 8 Provided M6.
Torque to stock specifications 7ft-lb [10N·m]
6. Install the SPDi unit onto the mounting bracket with
the 2 x 4mm bolts and nuts provided, place the relay on
the bottom of the mounting bracket as illustrated.

SPDi Plasma Ignition
Installation Manual
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7. Place the assembled unit as illustrated near the
driver's side of the hood latch, some small
modification of the body may be required to allow
the mount to sit flush. Once the bracket location is
determined, attach the provided paper sticker with
cross hairs, to mark the holes to be drilled. Confirm
this location has proper clearance for the wire
harness. Remove the mounting bracket and drill
17/64" [7mm] holes at the cross hair marked
locations.
8. Install the SPDi mounting bracket with the
provided 6mm bolts nuts and washers.
9. Place the ECU Interface Harness as illustrated. Do
not connect the harness to the SPDi unit yet. Connect
the relay plug to the relay under the SPDi mounting
bracket. Route the harness under the intake to the
valve cover. Route the power and ground to the battery
terminals. [Do not connect the battery connections]
10 A. Connect the SPDi ECU Interface Harness to the
stock ignition harness. [We recommend soldering the
connections for best performance and reliability] If
soldering is not possible, use the provided splice
connectors. [see 10 B for quick splice instructions]
Coil
ECU Harness
1999-2000
ECU Harness
2001-On
SPDi
Harness
1
Pin #3
Black/ Violet
Pin #3
Black/Blue
Blue
2
Pin #3
Black/Yellow
Pin #3
Black/Yellow
Orange
3
Pin #3
Black/Brown
Pin #3
Black/Brown
Purple
4
Pin #3
Black/Violet
Pin #3
Black/Violet
Yellow
1
Pin #1
Black/Violet
Pin #1
Black/Violet
Green
Connect Pin #1 on Cylinder 1 to SPDi ECU Interface
Harness Green Wire. This connection allows the stock
ignition to control the SPDi power relay.
Splice Into Stock Harness
At Least 1" Before Connector

SPDi Plasma Ignition
Installation Manual
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10 B. Quick Splice instructions (skip if soldering)
a) Place the stock ignition wire into the quick
splice connector.
b) Place the associated SPDi wire into the
quick splice connector.
c) Using pliers compress the metal splice
connector to make the connection.
d) Fold the protective cover until it clicks shut.
11.Place the Ignition Wire Harnesses as
illustrated. The Ignition Wire Harness is routed
behind the breather tube to the coils. Connect the
harness to the SPDi Unit. Connect to the coils
plugs.
12.Tuck the Ignition Wire Harness and the ECU
Interface Harness into the valve cover so all cables
are below coil height. Secure the harnesses with
the provided zip ties. The Engine cover may now
be reinstalled.
Notes:
a) Do not install SPDi without the relay
b) Do not install SPDi without the 10A inline
fuse.
c) Do not install a fuse larger than 10A.
Failure to install the relay or the 10A fuse could
result in damage to the SPDi unit.
13.Install the positive and negative SPDi power cables
to the battery terminals. The positive attachment can be
made at any location in the terminal box above the
battery. The negative cable can go direct to the
negative terminal of the battery. At this point reconnect
the negative battery terminal.
14.Connect the SPDi ECU Interface Harness to the
SPDi unit.
15. Installation is now complete. The SPDi system is
ready for use with the provided spark profile.
SPDi Spark is Programmable:
The SPDi control unit is programmable. It is possible to
upgrade the firmware and modify the spark profiles.
Changes to SPDi programming can be made by your
SPDi dealer. You may also program SPDi yourself with
the SPDi Programming Kit available at
www.spdispark.com.This kit includes a programming
cable and user interface software.
For Further Information Contact:
www.spdispark.com
[e-mail]
[e-mail]
Sphenic Technologies Inc.
4 Industrial Road, Unit 1
Kemptville, Ontario, Canada
K0G 1J0