wymiana świec 2.0.pdf

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 way guarantees success and

the author shall not be held responsible for any damage that is inflicted on your vehicle. Use this document

merely as a guide.

With that said lets begin! At the time when this document was written, my 1999.5 VW New Jetta GL has

56,xxx miles on the odometer. As I suspected, the spark plugs have never been replaced and a new set of

plugs is way overdue.

PARTS NEEDED:

1. Spark Plug Boot Tool

2. 4 NKG BKUR6ET-10 Spark Plugs. It has

a triple ground diode. It is pregapped.

3. Spark Plug socket + 10” extension +

elbow joint + ratchet

4. Various bits and screwdrivers

PREPARING FOR THE WORK:

1. Remove the engine cover. It simple and it is not covered in this document.

2. Locate the 4 plug wires and have a good look around them. The left-most and the right-most spark plug

wires are the easier ones. The middle two plug wires are the harder ones.

3. The hardest part of the process is removing the plug wire boots. Especially the middle two.

REMOVING THE PLUG WIRE BOOTS:

Step 1:

Locate the throttle cable. The

cable is held in place by two

plastic clips which are attached

to the intake manifold. Un-clip

the throttle cable and let loose.

This will minimize the chance of

breaking the clips while working

on the spark plugs:

This is the for upper clip ------>

This is for the lower clip ------>

Step 2 (plug #4) :

Slide the boot wire boot tool down plug wire #4 (the right-most one) till it has fully encased the plug

boot. Slightly twist the tool clockwise till it locks on its little teeth. Carefully pull towards you making sure that

you don't grab anything else but the boot of the plug wire.

If you have compressed air in a metal can, use it to blow away any dust and grime away from the spark

plug seat. This will prevent dirt entering the cylinder once the actual spark plug is removed.

Use the plug socket with the extension to unscrew the spark plug. If you used the correct socket, the

socket itself will grab the spark plug and you will be able to pull it out very easily. Replace the spark plug with

a new one. Use the boot tool again to reinstall the plug wire.

Step 3 (plug #3) :

This is little bit more complicated. In order to slide the boot tool down till it grabs the wire boot

completely, you will need to unplug the electrical connector of the 4 th injector and loosen the little plastic

cable rail that sits on top of the fuel rail. NOTE: you don't need to do anything to the fuel rail itself.

Here is how the fuel injector electrical connector looks

like. It has two metal pins that you need to squeeze by

hand until you hear 2 clicks, one click per pin. This is a

good indicator that the electrical connector has been

freed from the actual injector. Then you simply pop it

off.

Here is how the unplugged injector looks like. With

the electrical connector out of the way, you can

easily slide the boot tool down the plug wire and

remove the plug wires.

Here is how the plug socket tool

slides down to the spark plug.

You can clearly see that it is

pretty tight as it is now with the

injector unplugged.

STEP 4 (plug #2) :

This is the other “hard” to get

to plug boot. It is on the left,

passenger side of the intake

manifold. Again, you would

have to unplug the electrical

connector that goes for fuel

injector 1 to make room for the

boot tool. Since here you will

have bit less space I

recommend unclipping the little

cable rail that sits on top of the

fuel rail. It is like a guide for all

the wires that go in the

injectors.

Unplug this connector to allow

more movement of the cable

rail.

Unclip the cable rail from the

fuel pressure regulator and

wiggle it way. This will give you

extra space for the boot tool.

Here is how it looks:

One you have made way for the

boot tool, carefully remove the

plug wire boot and remove the

spark plug. Here is how close

the spark plug socket went in

between the injector and the

intake manifold:

STEP 5 (plug #1) :

This is the left-most spark plug. It is very easy to get to and should not cause you any trouble. There is plenty

of space to work with.

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