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VW Beetle Engine Spark Plugs Replacement Guide
How to change the engine spark plugs in a 2nd generation "New" 2012 to 2016 Volkswagen Beetle with the TSI 1.8L turbo I4 motor.

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2015 Beetle Turbo 1.8L
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Pull Off Plastic Engine Cover
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Ignition Coils Exposed

This automotive maintenance tutorial was specifically written to assist owners of the second generation (2012, 2013, 2014, 2015 & 2016 model year) "New" A5 VW Beetle in checking or changing the engine spark plugs in the TSI 1.8 liter inline four cylinder turbocharged motor.

Owners of other Volkswagen Group vehicles such as the Passat, CC, Tiguan, Golf, Touareg, Jetta, GTI, SportWagen, Eos, Rabbit, Bora, Vento, Lavida, Coccinelle, Maggiolino, Fusca, Audi A3, A4, S4, A6, S6, A7, A8, Q5, Q7, A5, S5, and TT may also find these DIY instructions to be helpful.

The OEM spark plugs are Genuine VW / Audi part number 06K-905-601-D or 06K905601D.

A few other compatible replacement spark plugs with their part numbers are as follows: Autolite 3923, Autolite AP3923DP2 and Champion KC8WYPB4 (9805).

Replacement OEM spark plugs can be purchased at your VW or Audi dealership's parts counter, at online Volkswagen parts retailer websites or from Amazon.

The tools needed to complete this procedure include a deep well 10mm socket, a flathead screwdriver, a 5/8" spark plug socket, a 6" extension bar, a ratcheting wrench and a tube of dielectric grease.

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Loosen Top 10mm Nut
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Remove 10mm Top Nuts
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Ground Nut Removed
The first two steps are to open the hood and then gently pull off the plastic engine cover.

Set the engine cover aside in a safe place.

Loosen the nuts on the top of each ignition coil or "coil pack" by turning them counterclockwise with the 10mm socket and a ratcheting wrench.

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4 10mm Nuts Removed
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Pull Off Ground Wire
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Deep Well 10mm Socket
Set the four 10mm nuts aside in a safe place.

Lift the ground cable's metal loop connector off the ignition coil bolt.

Loosen the ignition coil bolts by turning them counterclockwise with a deep well 10mm socket and a ratcheting wrench.

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Coil Pack Bolt Removed
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Four Ignition Coil Bolts
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Push In Release Tab
Set the four 10mm ignition coil bolts aside in a safe place.

Gently push in the release tabs on the four electrical connectors before sliding them out of their sockets.

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Disconnect Power Plugs
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Rotate Ignition Coil
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Lift Out Ignition Coil
Once all four of the power plugs are released from the ignition coils, you can move the bracket back and out of the way.

I'd recommend only checking or changing one spark plug at a time to help prevent from having debris fall down in to the cylinder head.

Rotate the ignition coil back and forth a few times to make sure that the rubber boot at the bottom of the ignition coil is not stuck to the top of the old spark plug.

Lift the ignition coil straight out of the spark plug well and set it aside in a safe place.

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VW Spark Plug Coil
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Spark Plug In Well
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5/8" Spark Plug Socket
Attach the 5/8" spark plug socket to a six inch extension bar and the 3/8" drive ratcheting wrench.



 

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Lower Over Old Spark Plug
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Spin Out Counterclockwise
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Lift Out Old Spark Plug
Lower the spark plug socket in to the well and attach it to the top of the old spark plug.

Carefully loosen the old spark by rotating it counterclockwise.

Try to avoid using excessive force to loosen the old spark plug to prevent from cracking the ceramic portion of the plug.

If you have trouble loosening the old spark plug, spray a small amount of penetrating oil such as PB Blaster, Liquid Wrench or Kano Kroil and wait at least 15-30 minutes before attempting to loosen it again. If you don't have any penetrating oil, try spraying some WD-40 or warm up the engine for a few minutes to help expand the metal engine block.

Once the old spark plug is loose, detach the ratcheting wrench from the extension bar and spin it out the rest of the way by hand.

Lift the old spark plug out of the well and detach it from the socket.
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Inspect Old Spark Plug
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Lower In New Spark Plug
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Tighten Clockwise

Inspect both ends of the old spark plug.

If the electrode end of the old spark plug looks ashy white, the plugs may have been exposed to high temperatures such as overheating or they may be the incorrect heat range for your driving conditions or environment.

On the other hand, if the old spark plug is grey or covered in dark black soot, the engine may be burning oil and should be examined by a professional mechanic.

An optional step is to apply some anti-seize lubricant grease to the threads on the new spark plug. Most spark plug manufacturers recommend that you not use anti-seize since it can lead to over tightening.

Push the new VW # 06K905601D spark plug in to the socket and lower it down in to the well.

Your spark plug socket should have a rubber insert or a strong magnet to hold it securely in place.

Spin in the new spark plug by hand in the clockwise direction until it makes contact with the cylinder head. Spinning it in by hand will help prevent from having the spark plug become cross threaded in the cylinder head.

Attach the 3/8" drive ratcheting wrench to the 6" extension bar and continue tightening the new spark plug in the clockwise direction.

If you are re-installing the old spark plug, tighten it to just a very small fraction of a turn past hand tight.

If you are installing a brand new spark plug, tighten it to just past the point when you feel the new crush washer collapse.

Do not over tighten the spark plug to prevent from cracking the ceramic body or stripping the aluminum threads.

If you used anti-seize grease, be very careful to not over tighten the spark plug.

Double check that the new spark plug is tight before moving on to the next steps.

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Apply Dielectric Grease
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Lower In Ignition Coil
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Re-Insert 10mm Bolt
Apply a small amount of dielectric grease to the opening in the rubber boot at the bottom of the ignition coil.

The dielectric grease will help keep out any debris or moisture and ensure a reliable electrical connection.

Lower in the ignition coil and rotate it a few times back and forth to help distribute the dielectric grease.

Re-insert the 10mm ignition coil bolt and spin it in a few turns in the clockwise direction by hand to prevent it from becoming cross threaded.

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Push In Electrical Connectors
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Tighten 10mm Clockwise
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10mm Ground Wire Bolt
Line up the four power plugs and gently push them back in to place.

Double check that the electrical connectors are secure.

Tighten the four ignition coil pack bolts by turning them clockwise with the deep well 10mm socket and ratcheting wrench until they are snug.

Try to avoid over tightening the ignition coil bolts to prevent from cracking the plastic ignition coil pack housings.

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Spin On 10mm Nut
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Tighten Clockwise
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Push On Engine Cover
Re-attach the ground wires to the top of the ignition coil modules.

Spin on the four 10mm nuts and tighten them in the clockwise direction.

Line up the plastic engine cover and push it back in to place.

Start the engine and listen for any strange sounds that may indicate a problem such as a faulty wire, disconnected power plug or a loose spark plug.

For more, check out my other 2012-2016 VW Beetle DIY Repair & Maintenance Guides.
 

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