MAINTENANCE 03-39

Spark plugs, replacing (2.5L engine)

Specification
• Spark plugs (2.5L engine)
Original equipment number . . . . . . . . . .101-905-600
Manufacturers number . . . . . . . . . .NGK PZFR 5J-11
Gap . . . . . . . . . .1.00 to 1.10 mm (0.039 to 0.043 in)

NOTE —
Volkswagen part numbers are given for reference only.
Always consult with your Volkswagen parts department
or aftermarket parts specialist for the latest parts infor-
mation.

– Switch off engine.

– Remove upper sound absorber panel. See Sound ab-

sorber panels, removing and installing in this repair
group.

0024861.tif ½ Disconnect harness connector from secondary air injec-

tion solenoid valve (arrow).

½ Attach puller T40039 to uppermost thick rib (arrow) of

each ignition coil.

• Lower ribs of coil may be damaged if they are used for

removal.
A02-0392.tif
• Harness connectors remain connected at this time.

• Ignition coils can carefully be pulled out using two flat

tipped screwdrivers if T40039 is not available.

– To prevent damage to wiring harness guide, do not re-

move wiring harness connectors until all ignition coils
have been slightly pulled out of spark plug shaft in two
stages.

½ Beginning with cylinder #1, pull all ignition coils approxi-

mately 10 mm (3/8 in) out of spark plug shaft using ignition
coil puller T40039 (arrow) or equivalent.
VB0703011.tif
– Again beginning with cylinder #1, pull all ignition coils out
another 10 mm (3/8 in) in the same order.
03-40 MAINTENANCE
½ Unclip and pull off all ignition coil connectors (A), begin-
ning at ignition coil #1.

– Remove ignition coils #1 - 5 from spark plug shafts.

0024862.tif

½ Remove and install spark plugs for each cylinder with

socket 3122B or equivalent.

NOTE —
M02-0186.tif
A 16 mm or 5/8 in socket with appropriate extensions is
suitable for spark plug removal and installation.

– When all spark plugs have been replaced and torqued to

specification, insert all ignition coils loosely into spark
plug shafts.

Tightening torque
• Spark plug to cylinder head (2.5L) . . 25 Nm (18 ft-lb)

– Align ignition coils to recesses in cylinder head cover.

– Connect all connectors to ignition coils in reverse order

of removal.

– Press ignition coils evenly onto spark plugs by hand.

– Install upper sound absorber panel.

 established 1950
Automotive Reference™

BentleyPublishers
.com

Volkwagen New Beetle

Service Manual: 1998-2010
including convertible
Price: $139.95
Bentley Stock No: VB10
Publication Date: 2010.sept.1
ISBN: 978-0-8376-1640-7
Hardcover, 8 3/8 in. x 11 in.
Case quantity: 1
1664 pages, 2647 photos, illustrations and diagrams

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Fully detailed exploded views
Features: including front body assembly.
50 Body-Front
• Maintenance procedures for everything from routine oil
changes to replacing key battery in remote control. This
manual tells you what to do and how and when to do it.
• Engine and cylinder head service, repair and recondition-
ing, including camshaft timing belt replacement.
• Explanation of Motronic 5.9.2, ME7 and Diesel Turbo
See how to perform routine
Direct Injection (TDI) engine management systems. maintenance procedures, such
as checking fluids.
• Emission control tests, repairs and adjustments, includ- 03 Maintenance
ing Exhaust Gas Recirculation (EGR) and Secondary Air
Injection (AIR) system.
Models, engines and transmissions
• Drivetrain maintenance, troubleshooting, adjustment and
covered
repair, including hydraulic clutch, gearshift linkage, and
drive axles. Models and engines
• Suspension component replacement, including front 1.8L turbo gasoline (engine code: APH, AWV, AWP,
struts, rear shocks, rear coil springs, and wheel bearing/hub BKF, BNU)
1.9L TDI diesel (engine code: ALH, BEW)
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2.0L gasoline (engine code: AEG, AVH, AZG, BDC,
• Coverage of ABS/EDL/ASR/ESP brake and drivetrain BEV, BGD
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• Heating and air conditioning repair, including A/C com- Transmissions (remove, install, external service)
ponent replacement Manual 5-speed 02J
Manual 5- and 6-speed 02M
Bentley repair manuals provide the highest level of clarity and Manual 5-speed 0A4
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Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235
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