How to Install a Coil Pack on a 2005 Passat

The Volkswagen Passat arrived on U.S. soil in the 1990 model year, but a slightly modified version of what the rest of the world knew as the Passat, which the U.S. market knew as the Dasher, was available as early as 1974. The 2005 model year was the final one for the third-generation Passat, as it was due for a complete overhaul the following year. The base-level gasoline-powered engine on the 2005 Passat was the 170-horsepower, 1.8-liter turbocharged four-cylinder. Replacing the coil pack on the 2005 Passats 1.8-liter engine is not overly difficult, but it does require a special tool.

Instructions

1

Loosen the three plastic screws securing the engine cover to the engine using a Phillips screwdriver. The screws only loosen; you cannot remove them. Lift the engine cover from the engine, exposing the four coil packs on the top, center of the engine in the middle of the valve cover.

2

Unplug the wiring harness from the failed coil pack by pressing and holding the unlocking button on the wiring harness and pulling the harness from the coil pack.

3

Line up the open end of a coil pack puller, Volkswagen tool No. T40039, with the top of the failed coil pack. Press the coil pack puller downward until you feel it click into place around the ribs on the top of the coil pack.

4

Grab the loop on the top of the coil pack puller and pull upward with a slight wiggling and twisting motion to remove the coil pack from the spark plug and the engine. Notice the coil pack has a long rubber tuber, known as the boot, which goes into a tube in the top of the valve cover and over the spark plug.

5

Position the replacement coil pack so its boot aligns with the top of the spark plug, and its electrical receptacle faces toward the coil pack wiring harness. Press the new coil pack downward until you feel it click into place on the top of the spark plug.

6

Plug the coil pack wiring harness into its receptacle on the top of the coil pack.

7

Repeat steps 2 through 6 to replace any additional failed coil packs.

8

Set the engine cover back on top of the engine, aligning its retaining screws with the screw holes in the engine cover brackets. Tighten the screws until they feel snug, using a Phillips screwdriver.