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Coil Pack and Spark Plug Wire Replacement
 
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Pelican Technical Article:

Coil Pack and Spark Plug Wire Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$200

Talent:

****

Tools:

Pliers, 5mm Allen head driver

Applicable Models:

VW Jetta (1999-05)

Parts Required:

Coil pack, spark plug wire set

Hot Tip:

Replace the wires and coil at the same time

Performance Gain:

Better running engine

Complementary Modification:

Replace spark plugs

The ignition system on the VW Jetta 2.0 uses a single coil pack and wires to each cylinder. This system is a step up from the old distributor ignition system, but can cause problems as the components age. With most Mk4 VW's reaching 100,000 miles or more, ignition system faults can leave you stranded without notice.

In this article, I'll go over the steps involved with replacing the coil pack and the wires. I recommend replacing both at the same time. It can be difficult to remove the old wires from the coil pack and you'll likely break off the connectors trying to remove them.

The coil pack on the 2.
Figure 1

The coil pack on the 2.0L engine is located under the secondary air pump. You'll also need to remove the engine cover. See our articles on Secondary Air Pump Removal and Engine Cover Removal for more information.

Begin by pressing the tab (green arrow) on the electrical connector and pulling it off the coil pack.
Figure 2

Begin by pressing the tab (green arrow) on the electrical connector and pulling it off the coil pack. Now loosen and remove the three 5mm Allen head bolts holding the coil pack in place. You may need to turn one of the spark plug wires to access one of the bolts. At this point, you can pull the wires off, but I recommend leaving them in place. It is easier to pull the other ends of the wires off the plugs and use it to match the new plug wires to the new coil pack.

Shown here is one of the spark plug wire/insulators (green arrow) that connects to each spark plug.
Figure 3

Shown here is one of the spark plug wire/insulators (green arrow) that connects to each spark plug. VW recommends the use of a special tool to remove these. I found a pair of long needle-nose pliers works equally as well. Make a mark on each to indicate which cylinder it goes to. Typically, I mark them left to right, numbers 1 thru 4.

Carefully move each old wire from under the intake manifold.
Figure 4

Carefully move each old wire from under the intake manifold. You'll notice that each wire fits into a series of plastic clips (green arrows) to hold it in place. Fit the new wires into the clips.

Shown here is what you'll probably encounter when you try to remove the wires from the coil packs.
Figure 5

Shown here is what you'll probably encounter when you try to remove the wires from the coil packs. Years of heat cycling as well as electrical discharging weakens the wire ends, causing them to snap off (green arrow) inside the coil pack. I recommend replacing the coil and wires together to prevent this problem.


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Comments and Suggestions:
ish Comments: Show me the order in which to set the plug leads
February 1, 2016
  Followup from the Pelican Staff: I don't have that info. The coil towers should be numbered. I will try to have that info added to the article. - Nick at Pelican Parts  

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