Tech Article Title Author Date
Spark Plug Installation (98.5 A4 Quattro 2.8) Jim Baulsir 2002

Tools Needed:

  • 6 - Spark Plugs (duh)
  • 1 - 5/8th inch thin walled spark plug socket (3/8th inch drive)
  • 1 - 12 inch extension (3/8th inch drive)
  • 1 - 3/8th inch drive ratchet
  • 1 - torque wench
  • 1 - medium Phillips screwdriver
  • 1 - 10mm socket
  • Electrical tape
  • Anti-seize compound - Optional (There are differing opinions on the use of Anti-seize compounds that I will not address here.)
Standard Disclaimer - Do this at your own risk. I take no responsibility. Works great on my car. Your mileage may vary. Yadda yadda.

Procedure

1) Remove all three engine covers and the air box cover
2) Remove the air intake to the air box.
3) Leave your hood open and let your car cool down if it is not already.

At this point you will see the 2.8L engine in all of its plumbed glory, no wonder they put those covers on. Now locate where the spark plug wires terminate at the heads, you will notice that #3, #5 and #6 will be difficult to reach, so...

4) We'll do the #1 plug first. Gently but firmly grab the top of the #1 wire and pull straight up while rocking back and forth (the wire, not you) until the wire comes loose.

You will now notice why you need a 12-inch extension. This is important - take a small piece of electrical tape and wrap it around three sides of the extension (the end that goes into the socket). Don't cover the little ball; this will tighten up the socket so you won't lose it in the hole.

5) Carefully insert the socket (on the end of the extension) into the spark plug hole until you feel the socket engage the plug (a little wiggling helps).
6) Make sure your ratchet is set to turn counter clockwise, put it on the end of the extension and start to unscrew the plug. You should only need the ratchet to loosen it, do the rest by hand and extract the plug.

Now comes installation of the new plug. Check the gap, if you use anti-seize remember just a dab, and don't put it closer than 4-5 threads to the electrode.

7) Insert the plug with the socket and extension and hand tighten, when you feel the plug "bottom out" put the torque wrench on it and tighten to 22 ft/lbs. Gently rock the socket out and reinstall the wire.

Repeat the procedure for numbers 2 and 4; numbers 3, 5 and 6 will be a little more difficult. Lets start with #3; to get to #3 you must remove the hose from the air box to the engine.

1) Loosen the hose clamps at both ends of the hose and remove.
2) Unplug the connector to the mass airflow sensor; remove the wire harness clip from the L bracket mounted to the forward lower bolt on the flange.
3) Using the 10 mm socket remove the 4 bolts and then the hose flange from the air box.
4) Now repeat the above procedure on plug #3.

For numbers 5 and 6 we'll need to move the coolant expansion tank.

1) Unscrew the three screws securing the expansion tank, carefully lift the tank forward; watch out for the wire under the tank. 
2) Gently move the tank to gain access to the #5 and #6 plugs.
3) Repeat the first procedure for #5 and #6

Now put every thing back together and your done.
 



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