In comparison to the three-day timing belt job, this really wasn't too bad. It was a 4 or 5 hour job. I had the same helper for the timing belt hang around to help me with the spark plugs. Here we go:
This was our working quarters.
These are the ignition wires. Each of the ignition wires lead out to a single spark plug. The other ends of each of the ignition wires all lead back to a coil pack, which would be at about the 5:00 position on the red circle I drew here.
A close-up of the ignition wires. They are numbered 1 through 4, one for each spark plug; ultimately, one for each cylinder in the engine.
Ordinarily you would remove the wires and spark plugs one-for-one. (This does not matter so much for spark plugs. A plug is a plug is a plug.) This is critical because of the ignition wires. It is smart to retrace your steps and ensure you are plugging the right wire back into the right plug. This is not a game of criss-cross! As a perk, the replacement wires I ordered from NGK were numbered 1-4 and matched exact length of each of my outgoing ignition wires.
The plugs for wires 1 & 2 were on the left side of the intake manifold of my engine. Plugs 3 & 4 were on the right side, much more obvious, and therefore, much easier to get pictures of. The wires were pried off with a simple tack-claw tool. Here is what the head of a plug looks like after you remove the wire:
Plugs 3 & 4 after the ignition wires were removed.
The plugs themselves were removed from the engine block by reaching in and fitting a special 'boot' tool around the head of the plug. Really all this 'boot' was was a socket with slits cut up the walls of it to fit around the sides of the plug, which had flanges that fit exactly up into the slits. Push and twist, and the plug threads back out of its port in the engine block!
The end of the ignition wire that fits around the spark plug. See the metal flanges that run along the length of the wire? Those are what the specialty 'boot' fits around.
Time for some more comparison pictures. With the first spark plug removed, here were my results:
I spy a 'VW' logo! The original spark plug out of the Beetle! Many many years of service out of this little guy.
Another view: top of the (used) spark plug. Burned out!
New spark plug, a la NGK Parts! Nice and shiny.
Another view: top of the new spark plug. Sparkly! (Get it?! Ha ha.)
Comparing old spark plug (left) and new spark plug (right).
Tops of old spark plug (left) and new spark plug (right).
More pictures:
All four ignition wires sitting out after the project was completed.
The spark plug ends of the wires.
The coil pack ends of the wires.
The new (blue!) ignition wires from NGK.
The coil pack ends of the new ignition wires. See how they are numbered 1 through 4?
Comparing old ignition wire to new ignition wire: head to head.
Side view: head-to-head of old versus new ignition wire. The only way you can figure which one is the original wire is just because of its dust! Otherwise it's in great shape. (That's my girl!)
Drumroll, please: the new wires were fished back into the Beetle (two had to go under the intake manifold) and simply pushed onto the heads of their spark plugs. (Push them on until they click.) Standing back looking at the engine room, here is our handiwork to admire:
The blue you see are the new wires! At the time this picture was taken, just a few car parts above the spark plugs had to be re-installed, like air tubes and engine covers.
A close-up on the right side of the intake manifold: all four wires wiggling down towards the coil pack.
A close-up on the left side of the intake manifold: showing where ignition wires 1 & 2 lead.
Once the leftover air tubes and engine cover were popped back on into place, the car was ready to start. Sure enough, the key turned in the ignition for me and she fired right up! First try, bingo! I was so proud!
Fresh and clean new sparks - this girl is getting ready for some road trips.
November, 2012 - end of the engine tune-up project!
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