MAINTENANCE 03-39

Spark plugs, replacing (2.5L engine)

Specification• Spark plugs (2.5L engine)

Original equipment number . . . . . . . . . .101-905-600Manufacturers number . . . . . . . . . .NGK PZFR 5J-11Gap . . . . . . . . . .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 departmentor 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 repairgroup.

Disconnect harness connector from secondary air injec-tion solenoid valve (arrow).

Attach puller T40039 to uppermost thick rib (arrow) ofeach ignition coil.

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

• Harness connectors remain connected at this time.

• Ignition coils can carefully be pulled out using two flattipped screwdrivers if T40039 is not available.

– To prevent damage to wiring harness guide, do not re-move wiring harness connectors until all ignition coilshave been slightly pulled out of spark plug shaft in twostages.

Beginning with cylinder #1, pull all ignition coils approxi-mately 10 mm (3/8 in) out of spark plug shaft using ignitioncoil puller T40039 (arrow) or equivalent.

– Again beginning with cylinder #1, pull all ignition coils outanother 10 mm (3/8 in) in the same order.

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03-40 MAINTENANCE

Unclip and pull off all ignition coil connectors (A), begin-ning at ignition coil #1.

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

Remove and install spark plugs for each cylinder withsocket 3122B or equivalent.

NOTE —A 16 mm or 5/8 in socket with appropriate extensions issuitable for spark plug removal and installation.

– When all spark plugs have been replaced and torqued tospecification, insert all ignition coils loosely into sparkplug 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 orderof removal.

– Press ignition coils evenly onto spark plugs by hand.

– Install upper sound absorber panel.

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Volkwagen New Beetle Service Manual: 1998-2010 including convertible

Price: $139.95Bentley Stock No: VB10Publication Date: 2010.sept.1ISBN: 978-0-8376-1640-7Hardcover, 8 3/8 in. x 11 in.Case quantity: 11664 pages, 2647 photos, illustrations and diagrams

The Volkswagen New Beetle Repair Manual: 1998-2010 is a comprehensive source of service information and specifica-tions for the New Beetle from 1998 to 2010. Whether you’re a professional or a do-it-yourself Volkswagen owner, this manu-al will help you understand, care for and repair your vehicle.

Features:

• 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 Direct Injection (TDI) engine management systems.

• Emission control tests, repairs and adjustments, includ-ing Exhaust Gas Recirculation (EGR) and Secondary Air Injection (AIR) system.

• Drivetrain maintenance, troubleshooting, adjustment and repair, including hydraulic clutch, gearshift linkage, and drive axles.

• Suspension component replacement, including front struts, rear shocks, rear coil springs, and wheel bearing/hub units.

• Coverage of ABS/EDL/ASR/ESP brake and drivetrain systems.

• Heating and air conditioning repair, including A/C com-ponent replacement

Models, engines and transmissions covered

Models and engines

1.8L turbo gasoline (engine code: APH, AWV, AWP, BKF, BNU)1.9L TDI diesel (engine code: ALH, BEW)2.0L gasoline (engine code: AEG, AVH, AZG, BDC, BEV, BGD2.5 L gasoline (engine code: BPR, BPS)

Transmissions (remove, install, external service)

Manual 5-speed 02JManual 5- and 6-speed 02MManual 5-speed 0A4Automatic 4-speed 01MAutomatic 6-speed 09GDSG 6-speed 02E

Fully detailed exploded views including front body assembly.50 Body-Front

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See how to perform routine maintenance procedures, such as checking fluids. 03 Maintenance

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Bentley repair manuals provide the highest level of clarity and comprehensiveness for service and repair procedures. If you’re looking an indispensable source concerning operation, mainte-nance and repair, look no further than Bentley.