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Discussion Starter · #1 ·
I have yet to find a picture-tutorial on spark plug replacement in a new beetle (GL) so I decided to take the time and write up this brief technical outline when I serviced my wifes car. While I was at it, I decided to upgrade the air filter and included that into this post. Hopefully this will help those of you interested in this easy DIY project. Sorry about the image resolution, the job was simple enough that I just used my iPhone for the photography as I went.
First gather a few simple tools to help make the job easier.
5/8" Swivel Magnetic Spark Plug Socket
Socket Wrench
Wobble drive extensions- necessary for the angle
Screw Driver -phillip and standard
Spark Plug gap measuring instrument
Spark Plug boot puller- again, VERY useful for $8.99
Components:
Dielectric lubricant
Spark Plugs, your choice- my local store had only the Autolites OE
Air Filter- I went with K&N "lifetime" high performance filter




Step one was to remove the engine cover, just pop off by pulling.

The engine compartment should look like this:

Now identify any wiring (highlighted with megenta circles) which must be disconnected to access the plugs (highlighted with green circles).
Cylinders 1/2

Cylinders 3/4

Remove the wiring harnesses by inserting a phillips head screw driver into the visible slot and turn gently, this will release the lock as you pull the harness out. Careful not to turn to far or the plastic fitting will break.

Now using the boot remover you can pull the rubber spark plug boots. This picture is only a demo of how I grabbed the boots, by the metal.

The end result should be like this:
Cyl 1/2

Now that every plug is exposed, spray the compartment with compressed air, even a keyboard cleaning can will do, just to remove dirt/debris from possibly entering the engine when we remove the plugs. Once that is complete, using the combination of ratchet extensions you can unscrew the plugs. Here they are:

I tested the old gap and it was as follows:
Cyl 1 0.045mm
 

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Discussion Starter · #2 ·
Sorry, first time posting, I pressed enter to soon.
To finish the post:
I had recorded the old gaps to be between 0.045 and 0.046mm.
Replace all parts in reverse order and be sure to add a little dielectric grease to the inside of the boots to make the next change easier.
I will post air filter separately
 

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Discussion Starter · #3 ·
Re: (Dr.DIY)

Here is the containment for the air filter, there are two screws on the side facing the engine compartment wall which need to be removed with the phillips head screw driver. Then you can life off the cover and replace the new filter, with a little elbow grease of course.

Just a few reminders and obvious things I forgot to mention in both these DIY posts:
Follow all safety rules and guidelines when working on your vehicle to protect yourself and your investment!
This is only a tutorial, I am not an expert, nor am I responsible for any damaged property or bodily injury. Please be advised, service your vehicle at your own risk! Or take it to a specialist.
 

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Re: 2001 Beetle 2.0L GL Spark Plug and Air Filter DIY Replacement (Dr.DIY)

Nice! I just pulled my manifold off, but this would have been helpful had I not gone that route. http://****************.com/smile/emthup.gif
 
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