Spark plugs — replacement (VW Golf 5)

Necessary tools and equipment:

• spark plug wrench, for example, HAZET 4766-1;
• appropriate pullers depending on the engine type;
• cars with 1.4-/1.6 liter engine BCA/BKG/BLN/BAG/BLF/BLP - puller VW-T10094 or HAZET 1849-7;
• cars with 1.6 liter engine BGU/BSE/BSF - puller VW-ST10112 or HAZET 1849-9;
• cars with 2.0 liter TFS1 engine AXW/BLRJBLX/BL Y/AHX- puller VW-T40039.

Attention! If the specified tools are not available, it will be necessary to dismantle parts that impede access to the plugs or ignition coils. It should be remembered that when using other tools to remove the coils, there is a risk, especially for a 2.0 liter engine, of damaging the ignition coil.

Materials required: 4 spark plugs of the appropriate specification.

Warning! I Only unscrew the spark plugs when the engine is cold or when its temperature is such that you can rest your hand on it. When removing the spark plugs from a hot engine, you can damage the threads in the spark plug sockets, which are installed on the cylinder head, which is made of light metal.

Cars with a 1.4-liter VSA petrol engine with a power of 55 kW (75 hp)

Removal

1. Unscrew the mounting bolts, remove the protective cover above the engine and place it with the upper side on a soft lining to avoid scratches, see the relevant chapter.

2. Use the VW-T10094 or HAZET 1849-7 puller to lift the ignition coils slightly upwards (see illustration).





3. Press the plug towards the ignition coil, squeeze the plug retainer lugs with your hand and disconnect the plug from the coil.

4. Remove the ignition coils.

5. Unscrew the spark plugs using a spark plug wrench, for example, V W-3122B or HAZET 4766-1 (see illustration).

Installation

6. Screw in the new spark plugs by hand until they touch the cylinder head and tighten them to 30 Nm.

7. Connect the power plugs to the coils and secure them.

8. Install the spark plugs on the ignition coils and align them with the openings on the cylinder head cover.

Attention! The coils must be fixed, which is accompanied by a distinct click.

9. Replace the protective cover over the engine, see the relevant chapter.

Vehicles with 1.4-/1.6-litre FSI engine BKG/BLN/BAG/BLF/BLP 66/85 kW (90/115 hp)

Removal

10. Unscrew the mounting bolts, remove the protective cover above the engine and place it with the top side on a soft lining to avoid scratches, see the relevant chapter.

11. Use a puller A, such as V W-T10094 or HAZET 1849-7, to lift the ignition coils slightly upwards (see illustration).



12. Press the ignition coil plug retainer using hook B, such as VW-T10118, and disconnect the plug from the coil (see illustration 15.11).

13. Remove the ignition coils.

14. Unscrew the spark plugs using a spark plug wrench, such as VW-3122B or HAZET 4766-1.

Installation

15. Screw in the new spark plugs by hand until they touch the cylinder head and tighten them to 30 Nm.

16. Place the VW-T10094 or HAZET 1849-7 puller on the ignition coils.

17. Connect the power plugs to the coils and secure them.

18. Install the spark plugs on the ignition coils, align them with the openings on the cylinder head cover and secure them by pressing them down with the puller.

19. Replace the protective cover over the engine, see the relevant chapter.

Cars with a 1.6-liter BGU/BSE/BSF petrol engine with a power of 75 kW (102 hp)

20. Unscrew the mounting bolts, remove the protective cover above the engine and place it with the top side on a soft lining to avoid scratches, see the relevant chapter.

21. Disconnect the connectors of the injectors of the 1st and 4th cylinders. Cylinder No.1 is located on the V-belt of the engine.

22. Remove the ignition coils using puller A, such as VW-T10112 or HAZET 1849-9 (see illustration).

Attention! If you do not have the above tools, you will need to dismantle the parts that make it difficult to access the ignition coil plugs. In this case, it is recommended that you have the spark plugs replaced by a workshop.

23. Unscrew the spark plugs using a spark plug wrench, such as VW-3122B or HAZET 4766-1.

Installation

24. Screw in the new spark plugs by hand until they touch the cylinder head and tighten them to 2.5 Nm

25. Connect the power plugs to the coils and make sure they are firmly seated.

26. Replace the protective cover over the engine, see the relevant chapter.

Vehicles with 2.0-liter (T)FSI engine AXW/BLR/BLX/BL Y/AXX with 110/147 kW (150/200 hp)

Removal

27. Unscrew the mounting bolts, remove the protective cover above the engine and place it with the top side on a soft lining to avoid scratches, see the relevant chapter.

28. Unscrew the two bolts 1 and remove the guide (see illustration).



29.Install the VW-T40039 puller (see A in the illustration) on the ignition coil so that the puller is secured only to the upper, thick projection 1 of the coil. If the puller is secured to the lower projections, they will break.



30. Pull the puller and lift the ignition coils about three centimeters (see arrow in illustration 15.29).

31. Press the plugs 2 to the ignition coils, squeeze the connector retainer leashes with your hand and disconnect the plugs from the coils (see illustration 15.28).

32. Remove the ignition coils from the cylinder head.

33. Unscrew the spark plugs using a spark plug wrench, for example, VW-3122B or HAZET 4766-1.

Installation

34. Screw in the new spark plugs by hand until they touch the cylinder head and tighten them to 25 Nm.

35. Install the ignition coils into their mounting holes so that the coil plugs can be connected.

36. Connect the ignition coil plugs and make sure they are securely seated.

37. Place the spark plug caps on the spark plugs and turn them by hand until they are secured.

38. Secure the wire guide with bolts.

39. Reinstall the upper engine protective cover, see the relevant chapter.

Spark Plug Socket Thread Renewal

Attention! If it turns out that the thread of the socket on the cylinder head where the spark plug is screwed in is damaged, then this thread must be renewed. BERU offers a corresponding repair kit for cutting a new thread. Using a special drill, grind down the damaged thread. The cylinder head does not need to be dismantled for this. Then cut a new thread in the socket and screw in the spark plug together with a special sealing insert. The inserts ensure a secure fit of the spark plugs and the required compression level.

Spark plugs for Golf/Touran cars

Attention! Due to constant technical changes, it may turn out that spark plugs with different parameters are required for certain types of engines. Therefore, when purchasing spark plugs, it is recommended to have the registration certificate with the vehicle identification number. The registration certificate also contains the three-digit engine code.