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    Volkswagen New Beetle Repair Manual: 1998-2010 - Excerpt

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    Bentley Publishers
    An excerpt from the Volkswagen New Beetle Repair Manual: 1998-2010, showing how to replace the spark plugs on the 2.5L engine. For more information on this new repair manual, visit http://www.bentleypublishers.com/product.htm?code=vb10

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    Volkswagen New Beetle Repair Manual: 1998-2010 - Excerpt

    Uploaded by

    Bentley Publishers
    15K views3 pages
    An excerpt from the Volkswagen New Beetle Repair Manual: 1998-2010, showing how to replace the spark plugs on the 2.5L engine. For more information on this new repair manual, visit http://www.bentleypublishers.com/product.htm?code=vb10

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    An excerpt from the Volkswagen New Beetle Repair Manual: 1998-2010, showing how to replace the spark plugs on the 2.5L engine. For more information on this new repair manual, visit http://www.bentleypublishers.com/product.htm?code=vb10

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    15K views3 pages

    Volkswagen New Beetle Repair Manual: 1998-2010 - Excerpt

    Uploaded by

    Bentley Publishers
    An excerpt from the Volkswagen New Beetle Repair Manual: 1998-2010, showing how to replace the spark plugs on the 2.5L engine. For more information on this new repair manual, visit http://www.bentleypublishers.com/product.htm?code=vb10

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    The document provides instructions for replacing spark plugs on a 2.5L engine and information about a service manual for the Volkswagen New Beetle.

    The steps include removing the upper sound absorber panel, disconnecting the secondary air injection solenoid valve connector, pulling out the ignition coils using a puller or screwdrivers, removing the ignition coil connectors, removing the spark plugs with a socket, installing new spark plugs, reinserting the ignition coils, reconnecting the ignition coil connectors, and reinstalling the upper sound absorber panel.

    The original equipment spark plug part number is 101-905-600. The manufacturers number is NGK PZFR 5J-11. The gap specification is 1.00 to 1.10 mm. The tightening torque for the spark plugs to the cylinder head is 25 Nm.

    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

    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.
    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)
    units.
    2.0L gasoline (engine code: AEG, AVH, AZG, BDC,
    • Coverage of ABS/EDL/ASR/ESP brake and drivetrain BEV, BGD
    systems. 2.5 L gasoline (engine code: BPR, BPS)

    • 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
    comprehensiveness for service and repair procedures. If you’re Automatic 4-speed 01M
    looking an indispensable source concerning operation, mainte- Automatic 6-speed 09G
    DSG 6-speed 02E
    nance and repair, look no further than Bentley.

    Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USA


    Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235
    http://www.bentleypublishers.com/contact-sales
    bentley_vb10_new.product.announcement.pdf

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