1/10/2022: Rev C

Added another version of the compression limiter bushing spacer. Has a hole diameter of 8mm as requested by a Thingiverse user.

8/17/2018 Update:

Modeled the OEM spacer that is used on the VW Touareg and other vehicles, P/N: 077 905 390. This style uses "press" fit studs that are inserted into the bolt holes. On 1.8T applications, this spacer normally requires trimming on the underside for it to sit flush on the valve cover. So, I uploaded two versions, one of the original part, and one that is already "trimmed".

5/2/2018 Update (revision B):

Uses a press fit compression limiter bushing. As the material heats up, it softens and due to the clamp pressure of the fasteners, the material undergoes "creep". This is when the material relaxes and is squished, then once the material cools and hardens the bolt loses it clamping load, which can lead to loosening, etc.

The bushing is sized for a hole diameter of 0.368"-0.372" and my printer prints holes about 5 thou or so undersized so in my model, the holes are sized as 0.375".

McMaster-Carr link to bushings: https://www.mcmaster.com/#91868a210

They are press fit, and can be installed easily with a small bench vise.

10/13/17 Update (revision A):

Added a 1mm radius fillet along the top edge of the spacer.

Description

In the Audi/VW community, a common modification for 1.8T and 2.7T engines is to use coilpacks from a newer model 2.0T direct injection engine. The 2.0T has a higher output coil and is mostly a plug and play modification depending on the engine code, however the coil is longer and sticks out of the cylinder head about 10mm. This spacer is simply used to fill that gap and help prevent dirt and debris from falling into the plug hole.

The spacer uses two (2) M6 socket cap screws to fasten it to the valve cover.

Many aftermarket companies offer this spacer, but made of billet aluminum. Each one is slightly different in shape, but important dimensions such as bolt hole size and spacing, thickness of spacer and coil hole size are the same.

Due to the temperatures in the engine bay, ABS or Nylon would be a suitable material choice.