Evo 4-9 DIY Coil-on-Plug Assembly Instructions

Step 1

Cut three 5-inch wires and three 16.25-inch wires. You should have 6 total wires in this group.

Step 2

Cut a second group with three 14-inch wires and three 18-inch wires. Keep this group separate from the first group.

Step 3

Strip 1/4 inch from one end and 1/2 inch from the other end of every wire. Be careful not to mix up the two wire groups.

Step 4

Twist the 1/2-inch ends of the 5-inch and 16.25-inch wires together. Repeat until all three pairs are joined at one end.

Step 5

Repeat the same joining process for the 14-inch and 18-inch wire group.

Step 6

Crimp an Evo male connector pin onto each joined wire end. Make sure no metal edges stick out, or the pin may not lock into the connector properly.

After crimping, pull on each pin lightly to confirm it is secure.

Step 7

Slide one insulator onto the doubled wires coming out of the Evo connector. Then slide individual insulators onto the single wires for the Denso connectors before attaching the Denso pins.

Step 8

Crimp Denso pins onto the end of each single wire. There should be 12 total across both wire groups. Do not insert them into the connectors yet.

Step 9

Insert the three joined 5-inch and 16.25-inch wires into one Evo male connector. Repeat with the 14-inch and 18-inch group on the second Evo connector.

You should hear a light click when each pin snaps into place. Tug each wire gently to confirm it is locked in. If one pin sits shorter than the others inside the connector, it is not fully seated and may cause a misfire.

This pin is not secured by the locking tab:

This pin is secured. Notice the difference in locking tab height:

You can use a small flathead screwdriver to help push the rubber insulators into the connector. Your harness should now look similar to this:

Step 10

Separate the shorter and longer wires coming from each Evo male connector by pulling them to opposite sides.

Step 11

Cut wire sheath lengths just long enough to cover each wire group.

Step 12

Starting with the shorter wire set, insert the +12V wire into the proper sheath and connect it to the Denso connector’s +12V port.

Step 13

Insert the Ground wire into the sheath and connect it to the Denso connector’s Ground port.

Step 14

Insert the Pulse wire into the sheath and connect it to the Denso connector’s Pulse port.

Step 15

Repeat the wiring process for the remaining connectors to complete the harness. You can use a 1 to 2 inch piece of wire plus another Denso pin and insulator to plug the unused Denso port and help keep water out.

Your finished harness should look similar to this:

Step 16

Clean the top of each coil with rubbing alcohol and let it dry before applying the JD logo. Peel off the transfer tape, center the logo, press firmly, and remove any bubbles before lifting the tape away.

Newer kits may include stickers that are easier to apply.

Step 17

Mount the coil packs to the mounting plate using the supplied hardware. The provided washers should go between the coil packs and the mounting plate so the coils sit flush.

Step 18

Mount the finished coil-on-plug setup to the valve cover using the supplied hex head bolts and washers. Plug the harness into both Evo connectors.

Step 19

Important: Replace the factory 10A fuse with the included 15A fuse. The COP ignition setup draws more power, and the factory fuse can eventually blow, which will prevent the car from starting.

For Evo 7/8/9, the fuse is in the interior fuse box by the driver’s left knee, top left, red fuse, position #1.

Step 20

Enjoy your finished DIY COP kit from JD Customs USA.