Spark Plugs, Replacing

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Special tools and workshop equipment required

Spark Plug Wrench 3122 B
Torque Wrench V.A.G 1331
Puller T40039
Puller T10094 A
Puller T10095
Removal/Installation Tool T10029
Puller T10112
Seal Puller T10118

2.5L

Removing

NOTE:

To pull off spark plugs, place T40039 on uppermost thick rib -arrow- of ignition coils with power output stages.

If lower ribs are used, these can be damaged

-- Remove engine cover. Refer to UPPER ENGINE COVER, REMOVING AND INSTALLING .

Spark plugs are located under ignition coils with power output stages.

Fig 1: Identifying Assembly Tool T10118 To Disconnect Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull off the connector -1- with T10118 in direction of -arrow-.

NOTE:

It is necessary to pull off the connector so that afterwards the ignition coils with power output stages with connected wires can be set aside without disturbing the routing of the wiring!

Fig 2: Identifying Ignition Coils Puller T40039

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull out all ignition coils with power output stages -1- upward using T40039.

NOTE:

Lines or connectors of ignition coils may remain connected when pulling out ignition coils with power output stages.

Note installation position of ignition coils with power output stages!

-- Set ignition coils with power output stages (with lines connected) carefully to the side.

CAUTION:

Make sure wires are not kinked or damaged.

Fig 3: Identifying Spark Plugs Unscrewed Using Spark Plug Removal Tool 3122 B

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove spark plugs using 3122 B.

Installing

-- Screw in new spark plugs using 3122 B and tighten to 20 Nm.

-- Guide ignition coils with power output stages into cylinder head and align ignition coils to designated recesses of cylinder head cover.

-- Press ignition coils with power output stages on to spark plugs up to stop, they must engage audibly.

-- Press the connector onto the exhaust gas recirculation valve until it is noticeably engaged.

NOTE:

Make sure that wiring of ignition coils with power output stages is routed properly.

-- Install engine cover. Refer to UPPER ENGINE COVER, REMOVING AND INSTALLING .

2.0L TFSI

Fig 4: Identifying Placement Of Ignition Coil Puller T40039 On Top Most Thick Rib Of Ignition Coils

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Removing

Perform the following:

NOTE:

To pull off spark plugs, place T40039 on topmost thick rib -arrow- of ignition coils with power output stages.

If lower ribs are used, these can be damaged

-- Remove engine covers. Refer to UPPER ENGINE COVER, REMOVING AND INSTALLING .

Spark plugs are located under ignition coils with power output stages -2-.

Fig 5: Location Of Ignition Coils With Power Output Stages And Harness Fasteners

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Note installation position of ignition coils with power output stages!

-- Remove both bolts -1-.

Fig 6: Identifying Ignition Coil Puller T40039

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull all ignition coils approximately 30 mm out of cylinder head in direction of arrow using T40039.

Fig 7: Identifying Direction To Disconnect Ignition Coils Connectors

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push connector in direction of ignition coils with power output stages, press catch down by hand and disconnect connectors -arrows-.

-- Remove spark plugs using 3122 B.

Fig 8: Identifying Removal/Installation Spark Plugs Using Spark Plug Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Plug designation and torque specification. Refer to IGNITION SYSTEM COMPONENT OVERVIEW

Observe waste disposal regulations!

Installing

-- Install new spark plugs using 3122 B.

Fig 9: Identifying Removal/Installation Spark Plugs Using Spark Plug Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide ignition coils with power output stages into cylinder head.

Fig 10: Identifying Direction To Connect Connectors To Ignition Coils

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align ignition coils with power output stages into designated recesses of cylinder head cover.

-- Connect all connectors to ignition coils -arrows-.

-- Press ignition coils with power output stages onto spark plugs by hand until stop. They must engage audibly.

Fig 11: Location Of Ignition Coils With Power Output Stages And Harness Fasteners

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure wiring using bolts -1-.

-- Install engine cover.

2.0L FSI and 2.0L TSI

Fig 12: Identifying Placement Of Ignition Coil Puller T40039 On Top Most Thick Rib Of Ignition Coils

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Removing

Perform the following:

NOTE:

To pull off spark plugs, place T40039 on topmost thick rib -arrow- of ignition coils with power output stages.

If lower ribs are used, these can be damaged

-- Remove engine covers. Refer to UPPER ENGINE COVER, REMOVING AND INSTALLING .

Spark plugs are located under ignition coils with power output stages -2-.

Fig 13: Location Of Ignition Coils With Power Output Stages And Harness Fasteners

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Note installation position of ignition coils with power output stages!

-- Remove both bolts -1-.

Fig 14: Identifying Ignition Coil Puller T40039

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull all ignition coils approximately 30 mm out of cylinder head in direction of arrow using T40039.

Fig 15: Identifying Direction To Disconnect Ignition Coils Connectors

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push connector in direction of ignition coils with power output stages, press catch down by hand and disconnect connectors -arrows-.

-- Remove spark plugs using 3122 B.

Fig 16: Identifying Removal/Installation Spark Plugs Using Spark Plug Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Plug designation and torque specification. Refer to IGNITION SYSTEM COMPONENT OVERVIEW

Observe waste disposal regulations!

Installing

-- Install new spark plugs using 3122 B.

Fig 17: Identifying Removal/Installation Spark Plugs Using Spark Plug Wrench

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide ignition coils with power output stages into cylinder head.

Fig 18: Identifying Direction To Connect Connectors To Ignition Coils

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Align ignition coils with power output stages into designated recesses of cylinder head cover.

-- Connect all connectors to ignition coils -arrows-.

-- Press ignition coils with power output stages onto spark plugs by hand until stop. They must engage audibly.

Fig 19: Location Of Ignition Coils With Power Output Stages And Harness Fasteners

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure wiring using bolts -1-.

-- Install engine cover.