4-Cyl. injection engine
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Servicin g ignitio n system Servicin Test Te st data, spark plug s
Engine codes Firing order Spark plugs1) VW/Audi Manufacturer's designation Electrode gap Torque settings 1)
1-3-4-2
BBY with automatic gearbox 1-3-4-2
101 000 033 AA NGK BKUR 6 ET-10 0.9...1.1 mm 30 Nm
101 000 062 AB NGK PZFR 5 D-11 1.0...1.1 mm 30 Nm
AUA, BBY, BBZ
The up-to-date figures and the spark plug change intervals:
=> Exhaust emissions test binder
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Spark plugs: Renew
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Spark plug s: Renew Renewing spark plugs, engine codes BUD, BTS
Chapter
→
Renewing spark plugs, engine codes AUA and AUB Chapter . →
Renewing spark plugs, engine codes AWY, BBY, BBZ, AXU, AZQ, BMD, BME, BKY, BUD, BTS Chapter . →
Renewing spark plugs, 1.8 l 5-valve engines
Chapter .
→
Special tools and workshop equipment required Spark plug socket and extension -VAS
3122B-
Puller -T40039-
Torque wrench -V.A.G 1331/- (5 -50 Nm)
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Spark plugs: Renew
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Assembly tool -T10118-
Puller -T10094
Rep. Gr.28
→
Renewing spark pl ugs, engine cod es BUD, BTS
– Carefully pull off hose -2-.
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Spark plugs: Renew
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– Unscrew the four bolts -1- and remove cover. – Install in reverse order. Bolt torque setting 10 Nm Renewing sp ark plug s, engi ne codes AUA and AUB Carry out the following procedure: – Remove engine cover
Chapter .
→
– Take off oil sealing cap -1-. – Take ignition cables -2- out of ignition cable guide -3- and pull ignition cable guide slightly upwards. – Pull off spark plug connectors and place ignition cables with ignition cable guide to side.
– Unscrew spark plugs using spark plug socket and extension -VAS 3122B-. – Screw in new spark plugs using spark plug socket and extension -VAS 3122B-. Note
Spark plug designation and torque setting
Rep. Gr.28
→
Observe disposal regulations!
– Fit spark plug connectors. – Press ignition cables -2- into ignition cable guide.
– Fit oil sealing cap -1-.
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Spark plugs: Renew
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– Installing engine cover
Chapter
→
Renewing spark pl ugs, engine cod es AWY, BBY, BBZ, AXU, AZQ, BMD, BME, BKY, BUD, BTS – Remove engine cover
Chapter .
→
Only valid for BUD and BTS:
– Carefully pull off hose -2-. – Unscrew the four bolts -1- and remove cover. Valid for all:
– Place Puller -T10094- on ignition coil with output stage -arrow-. – Slightly pull out ignition coil with output stage. – Fit assembly tool -T10118- as illustrated. – Release connection locking device carefully and pull off connector. – Pull out ignition coil with output stage.
– Unscrew spark plugs using spark plug socket
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Spark plugs: Renew
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and extension -VAS 3122B-. – Screw in new spark plugs using spark plug socket and extension -VAS 3122B-. Note
Spark plug designation and torque setting
Rep. Gr.28; Servicing ignition system, test data, spark plugs. →
Observe disposal regulations!
– Place puller -T10094- on ignition coil with output stage. – Slide connector on ignition coil with output stage until it audibly engages. – Push ignition coil with output stage in direction of arrow- into cylinder head. – Installing engine cover
Chapter
→
Only valid for BUD and BTS: – Fit cover and tighten bolts of cover to 10 Nm.
Renewing spark p lug s, 1.8 l 5-valve engines Removing: Note
To pull off spark plugs, fit puller -T40039- on
top, thick rib -arrow- of ignition coils with final output stages. If the lower ribs are used, they could be
damaged. Removing and installing engine cover -top Chapter →
– Remove bolts -arrows- from vacuum reservoir
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Spark plugs: Renew
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-A- and place vacuum reservoir to side with lines connected.
The spark plugs are located below the ignition coils with output stages -2-. Note
Note installation position of ignition coils with final output stages.
– Remove the two bolts -1-.
– Press connectors in direction of ignition coils
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Spark plugs: Renew
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with output stages, press onto catch by hand and pull connectors -arrows- off. – Pull all ignition coils out of cylinder head approx. 30 mm in direction of arrow using puller -T40039-.
– Unscrew spark plugs using spark plug socket and extension -3122 B-. Note
Spark plug designation and torque setting
Rep. Gr.28; Servicing ignition system, test data, spark plugs. →
Observe disposal regulations!
Installing – Screw in new spark plugs using spark plug socket and extension -3122 B- and tighten to correct torque setting.
– Insert ignition coils with output stages into cylinder head. – Align ignition coils with output stages in respective recesses of cylinder head cover. – Fit all connectors onto ignition coils -arrows-.
– Press ignition coils with output stages on
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Spark plugs: Renew
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spark plugs until stop by hand. They must be felt to engage.
– Secure cable guides with bolts -1-. – Install vacuum reservoir -A- and tighten bolts to 5 Nm. – Installing engine cover,
Chapter .
→
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Removing and installing engine cover -top-
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Removing and installing engine cover -topRemoving and installing engine cover -top-, 1.4 l 59 kW diesel engine Anchor . →
Removing and installing engine cover -top-, 1.4 l petrol injection engines Anchor . →
Removing and installing engine cover -top-, 1.2 l petrol injection engines Anchor . →
Removing and installing engine cover -top-, 1.4 l FSI engines Anchor . →
Removing and installing engine cover -top-, engine code BMD Anchor . →
Removing and installing engine cover -top-, engine code BNV Anchor . →
Removing and installing engine cover -top-, 1.9 l diesel engines Anchor . →
Removing and installing engine cover -top-, 1.8 l 5-valve engines Anchor . →
Removi ng and i nstall ing engi ne cover -top-, 1.4 l 59 kW diesel engine For this engine a two-part cover is used. – Remove cover at positions marked (dotted circles). Removing and installing engine cover -top-, 1.4 l petrol injection engines – Pull hose for oil separator or non-return valve off engine cover.
– Pull engine cover off mountings -arrows-. – Install in reverse order. Removing and installing engine cover -top-, 1.2 l petrol injection engines
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Removing and installing engine cover -top-
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– Pull off cover at positions marked -arrows-. – Install in reverse order. Removing and installing engine cover -top-, 1.4 l FSI engines – Pull off hose from air filter housing to camshaft housing. – Pull connector off intake air temperature sender. – Pull out oil dipstick.
– Pull off cover at positions marked -arrows-.
N24-1578
– Install in reverse order. Removing and installing engine cover -top-, engine code BMD – Pull off cover at positions marked -arrows-. Removing and installing engine cover -top-, engine code BNV – Pull out oil dipstick.
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Removing and installing engine cover -top-
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– Pull off cover at positions marked -arrows-. – For installing fit cover and press down until it is felt to engage. Reinsert oil dipstick. Removing and installing engine cover -top-, 1.9 l di esel engines Version 1
– Pull cover upwards at positions marked arrows--A- and -B- and pull out of guide forwards -C-. – Install in reverse order. Version 2 Removing: Note
The engine cover consists of two individual parts. 1. Outer part -A-, shaded in illustration.
2. Centre part -B-, not shaded in illustration.
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Removing and installing engine cover -top-
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– Disengage engine cover carefully at individual securing points and raise as follows. -1-, -3-, -2-, -4-.
– Remove outer part -1-. – Disengage centre part -2- also carefully and remove. Installing:
– Fit engine cover onto securing points arrows- and press on.
– Then fit outer part -1- at securing points -
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Removing and installing engine cover -top-
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arrows- and press on, so that cover engages.
Removing and installing engine cover -top-, 1.8 l 5-valve engi nes Removing: – Disengage engine cover -1- at securing points -arrows B- and raise. – Then pull out of bracket -arrow A-, Installing: – First fit engine cover -1- at securing point arrow A-. – Then fit engine cover -1- at the other securing points -arrows B- and press on, until they noticeably engage.
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