Spark Plug replacement on VW 2.

0L engine with AEG code

This is document is an attempt to describe and illustrate to some extent the process of replacing the spark plugs on a Volkswagen 2.0L engine with AEG engine code. This document in no wa guarantees success and the author shall not be held responsible for an damage that is inflicted on our !ehicle. "se this document merel as a guide. #ith that said lets begin$ At the time when this document was written% m &'''.( V# )ew *etta GL has (+%xxx miles on the odometer. As , suspected% the spark plugs ha!e ne!er been replaced and a new set of plugs is wa o!erdue. PARTS EE!E!" &. -park .lug /oot Tool

2. 0 #G $#%R&ET'(0 -park .lugs. ,t has a triple ground diode. ,t is pregapped.

1. -park .lug socket 2 &03 extension 2 elbow 4oint 2 ratchet

0. Various bits and screwdri!ers

PREPAR) G *+R T,E W+R#" &. 5emo!e the engine co!er. ,t simple and it is not co!ered in this document. 2. Locate the 0 plug wires and ha!e a good look around them. The left6most and the right6most spark plug wires are the easier ones. The middle two plug wires are the harder ones. 1. The hardest part of the process is remo!ing the plug wire boots. Especiall the middle two. RE-+V) G T,E PL%G W)RE $++TS" Step (" Locate the throttle cable. The cable is held in place b two plastic clips which are attached to the intake manifold. "n6clip the throttle cable and let loose. This will minimi7e the chance of breaking the clips while working on the spark plugs8 This is the for upper clip 6666669

This is for the lower clip 6666669

Step 2 :plug ;0<" -lide the boot wire boot tool down plug wire ;0 :the right6most one< till it has full encased the plug boot. -lightl twist the tool clockwise till it locks on its little teeth. =arefull pull towards ou making sure that ou don>t grab an thing else but the boot of the plug wire. ,f ou ha!e compressed air in a metal can% use it to blow awa an dust and grime awa from the spark plug seat. This will pre!ent dirt entering the c linder once the actual spark plug is remo!ed. "se the plug socket with the extension to unscrew the spark plug. ,f ou used the correct socket% the socket itself will grab the spark plug and ou will be able to pull it out !er easil . 5eplace the spark plug with a new one. "se the boot tool again to reinstall the plug wire. Step . :plug ;1<" This is little bit more complicated. ,n order to slide the boot tool down till it grabs the wire boot completel % ou will need to unplug the electrical connector of the 0th in4ector and loosen the little plastic cable rail that sits on top of the fuel rail. +TE" /ou don0t need to do an/thing to the 1uel rail it2el1. ?ere is how the fuel in4ector electrical connector looks like. ,t has two metal pins that ou need to s@uee7e b hand until ou hear 2 clicks% one click per pin. This is a good indicator that the electrical connector has been freed from the actual in4ector. Then ou simpl pop it off.

?ere is how the unplugged in4ector looks like. #ith the electrical connector out of the wa % ou can easil slide the boot tool down the plug wire and remo!e the plug wires.

?ere is how the plug socket tool slides down to the spark plug. Aou can clearl see that it is prett tight as it is now with the in4ector unplugged.

STEP 3 :plug ;2<" This is the other Bhard3 to get to plug boot. ,t is on the left% passenger side of the intake manifold. Again% ou would ha!e to unplug the electrical connector that goes for fuel in4ector & to make room for the boot tool. -ince here ou will ha!e bit less space , recommend unclipping the little cable rail that sits on top of the fuel rail. ,t is like a guide for all the wires that go in the in4ectors. "nplug this connector to allow more mo!ement of the cable rail.

"nclip the cable rail from the fuel pressure regulator and wiggle it wa . This will gi!e ou extra space for the boot tool. ?ere is how it looks8

Cne ou ha!e made wa for the boot tool% carefull remo!e the plug wire boot and remo!e the spark plug. ?ere is how close the spark plug socket went in between the in4ector and the intake manifold8

STEP 4 :plug ;&<" This is the left6most spark plug. ,t is !er eas to get to and should not cause ou an trouble. There is plent of space to work with.

STEP &" 5eassemble e!er thing back the wa it was. Dake sure all the fuel in4ectors are plugged in and seated properl . Dake sure none of the plug wires is touching the intake manifold or other parts of the engine that get heated. Dake sure the plug wires are guided with the little clips properl . =heck to see if the main connector on step 0 is reconnected. STEP 5" After ou made sure e!er thing is fine and dand % turn ou ignition ke on without starting the engine and let it sit like that for &0 seconds. -tart our engine and see how it works. ,f all is fine go to... STEP 6" 5einstall the engine co!er% collect all our tools and ha!e a beer$ A!!)T)+ AL ) *+" According to the /entle Danual% the spark plugs must be changed e!er 20E miles. ?ere is how a (+E mile spark plug looks like compared to a brand new one8 Aou can clearl see the burnt on deposits on the ground diodes. Also% note how the middle diode is shorter than the newer one. The middle diode is supposed to be round. Cn m old spark plugs% the wear was so ob!ious that the middle diode was more triangular rather than round. This increased the spark plug gap causing weak sparking and poor engine performance and increased fuel consumption.

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