Volkswagen Cars 2000-05

Spark Plugs 2

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Removal & Installation



1.8L (Aww And Awp) Engines

NOTE
This procedure requires the use of the following special tools, or their equivalents:



Spark plug wrench VAS 3122B
 
Seal puller T10018
 
Removal/Installation tool T10029
 
Puller T10095
 
Torque wrench V.A.G 1331/ (5 - 50 Nm)
 

  1. Make sure you have the radio code, if necessary.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Loosen the retaining screws, and remove engine cover upward.

    Click image to see an enlarged view

    Fig. Loosen the screws (arrows), then remove the engine cover

  6.  
  7. Remove the hex nut (arrow) and vacuum reservoir (1).

    Click image to see an enlarged view

    Fig. Remove the hex nut (arrow) and vacuum reservoir (1)

  8.  
  9. Unfasten the screws (arrows) and remove the vacuum reservoir bracket (1).

    Click image to see an enlarged view

    Fig. Unfasten the screws (arrows) and remove the vacuum reservoir bracket (1)

  10.  
  11. Remove ignition coils together with spark plug connectors manually.

    Click image to see an enlarged view

    Fig. Remove ignition coils together with spark plug connectors manually

  12.  
  13. Remove spark plugs using Spark plug wrench VAS 3122B.
  14.  
  15. Inspect the spark plugs, as outlined in this section.

    Click image to see an enlarged view

    Fig. Spark plug applications-1.8L (AWW and AWP) Engines

  16.  

To install:

  1. Install spark plugs with spark plug wrench and tighten to 22 ft. lbs. (30 Nm).

    Click image to see an enlarged view

    Fig. Use a spark plug wrench to install and tighten the spark plugs

  2.  
  3. Install the ignition coils together with spark plug connectors.
  4.  
  5. Install the vacuum reservoir bracket and tighten the screws.
  6.  
  7. Install the vacuum reservoir and tighten the hex nut.
  8.  
  9. Place engine cover and tighten screws.
  10.  
  11. Connect the negative battery cable.
  12.  

1.8L Engine
  1. Make sure you have the radio code, if necessary.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the retainers and the engine cover.
  6.  
  7. Unscrew the bolts from vacuum reservoir and set vacuum reservoir with lines connected aside.
    NOTE
    Tag or note the installed position of the ignition coils before removing them.



    Click image to see an enlarged view

    Fig. Unscrew the bolts (1) from vacuum reservoir (2) and set vacuum reservoir with lines connected aside

  8.  
  9. Disconnect the harness connector for ignition coil with power output stage, then carefully pull off the ignition coil with power output stage from spark plug.

    Click image to see an enlarged view

    Fig. Disconnect the harness connector for ignition coil with power output stage (arrow), then carefully pull off the ignition coil with power output stage from spark plug

  10.  
  11. Unscrew spark plugs using a spark plug removal socket
  12.  
  13. Inspect the spark plugs as outlined in this section.
  14.  

To install:

  1. Install the spark plugs using a spark plug wrench and tighten to 22 ft. lbs. (30 Nm).
  2.  
  3. Carefully connect the ignition coil with power output stage by hand on to spark plug.
  4.  
  5. Attach the connector for ignition coil with power output stage, as tagged during removal.
  6.  
  7. The remainder of installation is the reverse of the removal procedure.
  8.  

With Intermediate Shaft
  1. If necessary, make sure you have the radio code.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the top engine cover.
  6.  
  7. Remove the ignition coils with the spark plug connectors and carefully pull upward. Detach the spark plug connectors using spark plug connector tool T10029, or equivalent tool.

    Click image to see an enlarged view

    Fig. Remove the ignition coils with the spark plug connectors (2) and carefully pull upward. Detach the spark plug connectors (2 - center and bottom) using a suitable spark plug connector tool

  8.  
  9. Remove spark plugs using spark plug wrench 3122 B, or equivalent wrench.
  10.  

To install:

  1. Screw in new spark plugs using spark plug removal tool 3122 B and tighten to 22 ft. lbs. (30 Nm).
  2.  
  3. Attach the ignition coils- with spark plug connector and tighten. Use the spark plug connector tool to attach the spark plug connectors.
  4.  
  5. Check ignition cables and connectors for proper connections.
  6.  
  7. Install engine cover.
  8.  
  9. Connect the negative battery cable.
  10.  

Without Intermediate Shaft

NOTE
You will need ignition coil puller T40039, or equivalent tool to remove the ignition coils.

  1. If necessary, make sure you have the radio code.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the top engine cover.
  6.  
  7. The spark plugs are situated under the ignition coils with power output stages (2).
    NOTE
    Before removing, tag or note the installed position of ignition coils with power output stages!

  8.  
  9. Unfasten both bolts (1).
    NOTE
    Place the ignition coil puller T40039 on the topmost thick rib of ignition coils with power output stages. If lower ribs are used, these can be damaged



    Click image to see an enlarged view

    Fig. The spark plugs are under the ignition coils with power output stages (2). Before removing, tag or note the installed position of ignition coils with power output stages. Unfasten both bolts (1).

  10.  
  11. Pull the ignition coils about 30mm out of cylinder head in the direction of the arrow shown, using ignition coil puller T40039, or equivalent tool.

    Click image to see an enlarged view

    Fig. For coil removal, place the ignition coil puller T40039 on the topmost thick rib (arrow) of ignition coils with power output stages.



    Click image to see an enlarged view

    Fig. Pull the ignition coils about 30mm out of cylinder head in the direction of the arrow shown, using the ignition coil puller.

  12.  
  13. Push the connector in direction of ignition coils with power output stages, press the catch down with your hand, then detach the connectors (arrows).

    Click image to see an enlarged view

    Fig. Push the connector in direction of ignition coils with power output stages, press the catch down with your hand, then detach the connectors (arrows)

  14.  
  15. Remove spark plugs using spark plug wrench 3122 B, or equivalent suitable spark plug wrench.
    NOTE
    Properly dispose of used spark plugs!



    Click image to see an enlarged view

    Fig. Use a suitable spark plug wrench to remove the spark plugs

  16.  

To install:

  1. Screw in new spark plugs using spark plug removal tool 3122 B and tighten to 22 ft. lbs. (30 Nm).
  2.  
  3. Guide the ignition coils with power output stages into the cylinder head.
  4.  
  5. Align the ignition coils with power output stages into designated recesses of cylinder head cover.
  6.  
  7. Attach all connectors to ignition coils.
  8.  
  9. Press the ignition coils with power output stages onto spark plugs by hand until stop. You will hear an audible click as properly engage.
  10.  
  11. Secure the wiring using bolts.
  12.  
  13. Install engine cover.
  14.  
  15. Connect the negative battery cable.
  16.  

2.0L (Aeg, Avh, Azg, Bbw, Bev) Engines

NOTE
This procedure requires the use of the following special tools, or their equivalents:



Spark plug wrench VAS 3122B
 
Seal puller T10018
 
Removal/Installation tool T10029
 
Puller T10095
 
Torque wrench V.A.G 1331/ (5 - 50 Nm)
 

  1. Make sure you have the radio code, if necessary.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Pry the plugs out (arrows), then remove the nuts underneath.
  6.  
  7. Remove the nut (1).

    Click image to see an enlarged view

    Fig. Pry the plugs out (arrows), then remove the nuts underneath. Remove the nut (1)

  8.  
  9. Pull out oil dipstick.
  10.  
  11. Remove engine cover.

    Click image to see an enlarged view

    Fig. Spark plug applications-2.0L (AEG, AVH, AZG, BBW, BEV) Engines

  12.  
  13. Remove the spark plug connector (arrows) using tool T10029.
  14.  
  15. Remove the spark plug using Spark plug wrench VAS 3122B.
  16.  
  17. Inspect the spark plugs, as outlined in this section.

    Click image to see an enlarged view

    Fig. Remove the spark plug connector (arrows) using tool T10029 and remove the spark plug using Spark plug wrench VAS 3122B (arrow)

  18.  

To install:

  1. Install spark plugs with Spark plug wrench VAS 3122B. Tighten to 22 ft. lbs (30 Nm).
  2.  
  3. Install spark plug connectors using Removal/Installation tool T10029
  4.  
  5. Check that ignition wiring and spark plug connectors are seated securely.
  6.  
  7. Install engine compartment cover.
  8.  
  9. Connect the negative battery cable.
  10.  

2.0L Engine
  1. Loosen clamp screws and remove engine cover upward.
  2.  
  3. Disconnect connectors for fuel injectors of first and fourth cylinders.
  4.  
  5. Tag, then disconnect the spark plug connectors using puller T10112, or equivalent tool.

    Click image to see an enlarged view

    Fig. Use a suitable tool to detach the spark plug connector

  6.  
  7. Unscrew spark plugs using a spark plug socket.
  8.  
  9. Inspect the spark plugs, as outlined in this section.
  10.  

To install:

  1. Install new spark plugs using a spark plug wrench, and tighten to 22 ft. lbs. (30 Nm).
  2.  
  3. Connect spark plug connectors using puller T10112 .
  4.  
  5. Check ignition cables and connectors for proper connections.
  6.  
  7. Insert engine cover and secure with the clamp screws.
  8.  

2.5L Engine

NOTE
You will need ignition coil puller T40039, or equivalent tool to remove the ignition coils.

  1. Make sure you have the radio code, if necessary.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine cover
    NOTE
    The spark plugs are located under ignition coils with power output stages. Before removing, tag or note the installed position of ignition coils with power output stages!

  6.  
  7. Pull out all ignition coils with power output stages upward using ignition coil puller T40039, or equivalent tool.
    NOTE
    The lines or connectors of ignition coils can stay connected when pulling out the ignition coils with power output stages.



    Click image to see an enlarged view

    Fig. For coil removal, place the ignition coil puller T40039 on the topmost thick rib (arrow) of ignition coils with power output stages.



    Click image to see an enlarged view

    Fig. Pull out all ignition coils with power output stages (1) upward using ignition coil puller T40039

  8.  
  9. Set ignition coils with power output stages (with lines connected) carefully to the side.
    WARNING
    Make sure not to kink or damage the wires!

  10.  
  11. Unscrew spark plugs using spark plug removal tool 3122 B .
  12.  
  13. Inspect the spark plugs, as outlined in this section.
  14.  

To install:

  1. Screw in new spark plugs using spark plug a suitable spark plug socket and tighten to 15 ft. lbs. (20 Nm).
  2.  
  3. Guide the ignition coils with power output stages into cylinder head and align the ignition coils to the designated recesses of cylinder head cover.
  4.  
  5. Press ignition coils with power output stages on to spark plugs until the stop; when connected properly, they will engage audibly.
    NOTE
    Make sure the ignition coil wiring is properly routed.

  6.  
  7. Install the engine cover.
  8.  

2.8L (Afp) Engine

NOTE
This procedure requires the use of the following special tools, or their equivalents:



Spark plug wrench VAS 3122B
 
Seal puller T10018
 
Removal/Installation tool T10029
 
Puller T10095
 
Torque wrench V.A.G 1331/ (5 - 50 Nm)
 

  1. Make sure you have the radio code, if necessary.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Pull the spark plug connector off using Removal/Installation tool T10029, or equivalent tool.

    Click image to see an enlarged view

    Fig. Pull the spark plug connector off using Removal/Installation tool T10029, or equivalent tool

  6.  
  7. Remove the spark plugs using Spark plug wrench VAS 3122B or equivalent.

    Click image to see an enlarged view

    Fig. Remove the spark plugs using Spark plug wrench VAS 3122B or equivalent

  8.  
  9. Inspect the spark plugs, as outlined in this section.

    Click image to see an enlarged view

    Fig. Spark plug applications-2.8L (AFP) Engines

  10.  

To install:

  1. Install spark plugs with spark plug wrench and tighten to 18 ft. lbs. (25 Nm).
  2.  
  3. Install spark plug connectors using Removal/Installation tool T10029 .
  4.  
  5. Check that ignition wiring and spark plug connectors are seated securely.
  6.  
  7. Connect the negative battery cable.
  8.  

2.8L (Bdf) Engine

NOTE
This procedure requires the use of the following special tools, or their equivalents:



Spark plug wrench VAS 3122B
 
Seal puller T10018
 
Removal/Installation tool T10029
 
Puller T10095
 
Torque wrench V.A.G 1331/ (5 - 50 Nm)
 

  1. Make sure you have the radio code, if necessary.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine cover (1).

    Click image to see an enlarged view

    Fig. Remove the engine cover (1)

  6.  
  7. Release ignition coil connector (1) from the ignition coil (2) and remove.

    Click image to see an enlarged view

    Fig. Release ignition coil connector (1) from the ignition coil (2) and remove

  8.  
  9. Remove ignition coils using Puller T10095 .
  10.  
  11. Remove spark plugs using Spark plug wrench VAS 3122B, or equivalent.

    Click image to see an enlarged view

    Fig. Remove spark plugs using Spark plug wrench VAS 3122B, or equivalent

  12.  
  13. Inspect the spark plugs, as outlined in this section.

    Click image to see an enlarged view

    Fig. Spark plug applications-2.8L (BDF) engine

  14.  

To install:

  1. Install spark plugs with spark plug wrench and tighten to 22 ft. lbs. (30 Nm).
  2.  
  3. Push the ignition coils onto the spark plugs.
  4.  
  5. Push the ignition coil connectors onto ignition coils and make sure they are properly engaged.
  6.  
  7. Check that ignition wiring and spark plug connectors are seated securely.
  8.  
  9. Install engine cover and clip securely in position.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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