DIY spark plug change RS6 C5

4.2 V8 40v biturbo - 450 bhp
4.2 V8 40v biturbo - 480 bhp (plus)
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Shoppinit
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DIY spark plug change RS6 C5

Post by Shoppinit » Thu Oct 08, 2009 9:30 am

EDIT: Before installing, make sure you have genuine NGK plugs and not counterfeit:

http://www.ngk-sparkplugs.jp/english/te ... index.html

Right, as requested... Not saying this is the best way, just my way :)

You will need:

1. Large flat blade screw driver
2. 10mm socket with extension
3. 16mm plug socket with plug gripper
4. 180mm at least socket Extension (it's a long way down there)
5. Torque wrench

Steps:

1. Remove front carbon fiber cover in the usual way.
2. Loosen jubilee clips on the intake funnel boots. Completely loosen all 4 clips.
3. Remove the front intake scoops. There are 2 self-tappers that hold each on on the front valence. Remove these screws.

They are a pain to get out because there are coolant pipes that stop you pushing them back and out. YOu can compress the cooland pipes slightly and slide them out laterally. I foundthis to be the easiest way. So you slide the left one left, and the right one right and out.

At the same time, you need to detach the boot / hose from the air box.

Once you've done that you should have this:

Image


4. Remove the nut from the air cleaner box retaining bolt (left side). You'll have to access it from underneath. Easiest to do this with the 10mm socket if your wrench is small enough.

Image

5. Then remove the bolt on the air box fixing bracket (right side):

Image

6. Remove the Allen bolt from the center front of the airbox and don't drop it in the engine bay (like I did).

7. Now prise up the BACK of the air box by gently lifting it with your fingers. You're trying to slide the MAF tubes out of the inlet manifold receptacles. It's quite a tight fit, so try to lift the air box UP without twisting it forwards. It'll come up about 2 inches then you'll feel it pull free of the inlet manifold. DON'T PULL IT ANY FURTHER!!

8. The air box is still connected to the car via the electrical connectors on each MAF. These are right at the back of the airbox (bulkhead side) You need to disconnect them BOTH before completely removing the airbox.

Here is the left-side connector (the one on the right is the same, but slightly hidden by other cables in front of it. If you are the kind of person that gets annoyed easily then gather your reserves of patience for the right side.
(These connectors have a little tab that you need to lift before they release. I use a large flat blade screw driver that I twist, then I pull the connectors off. See below where I disconnect the coil packs for a photo. )

Image

9. Now you can remove the whole airbox and put it to one side. Be careful with it, it would be a shame to scratch the carbon fiber or break a MAF. Don't put it anywhere dirty either because those MAFs are going to go straight back into the manifold and you don't want to drop any gunk in there. In this photo I've highlighted the DVs for those that are interested.

Image

Here is the underside of the airbox showing the MAFs:

Image

10. Use clean cloth (lint-free) or sponge or something to cover the inlet manifold openings to stop anything falling in there. You know that sods law means that if you don't, something will fall in there.

11. Now the coil packs are exposed. Yay! Should all be plain sailing now, right? Yeah, right.
Starting on the left bank, disconnect the electrical connectors on each coil pack. Use a flat blade screwdriver twisted in the slit to release the retaining tab and slide the connector off. Plop. Simple :)

Image

Now loosen the 2 bolts on each coil pack with your 10mm socket.

12. Just as you were thinking that this is going to be easy from now on, the coil pack proves impossible to remove because of all the bits in front of it. Remove the cylinder and tube from in front of the coil pack and lay it on top (on a bit of rag since this is a crankcase breather and may drip oil onto your engine).

Image


13. Remove the first coil pack. Mine stank, don't know why. Put it to one side. The plug is exposed.

Image

14. Remove the plug in the usual fashion. Mine looked like this:

Image

The tip looks good, but what's all that brown crap on the thread? Also, my plugs were barely more than finger tight. I think Audi forgot to torque them up last time :shock:

15. Replace the plug with a new one. Torque it up to 30Nm (thanks, grizz).
Replace the coil pack and tighten it to the head. Plug the connector back in. This one is done.

16. Coil pack 2 is difficult to remove because of the stainless steel pipework in front of it.
Image

It's easy enough to move them by removing the Allen bolts and pushing them out of the way.
Image

17. The others are easy to remove and replace.

18. In true Haynes fashion "refitting is reverse of removal".

Just make sure that the MAFs are bedded properly in their holes.

Take the car out for a run, then test for misfiring with the vagcom if you've got one.

Peasy easy. Any comments welcome. :thumbs:
That's it
Last edited by Shoppinit on Sun Nov 15, 2015 12:26 pm, edited 3 times in total.
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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RE: DIY spark plug change RS6 C5

Post by Daveperc » Thu Oct 08, 2009 9:38 am

Great write up thanks!

My only comment would be that I wouldn't put my socket set up on the bulkhead (see photo at step 9) as it's ideally placed to tip its contents into the air inlets!

Well done - did you work for Haynes??!!

Dave

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Shoppinit
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Re: RE: DIY spark plug change RS6 C5

Post by Shoppinit » Thu Oct 08, 2009 9:45 am

Thanks :) I'm glad to be able to give something back.
Daveperc wrote:I wouldn't put my socket set up on the bulkhead (see photo at step 9) as it's ideally placed to tip its contents into the air inlets!
Good point. This is my one of my biggest flaws. I'm forever putting tools in stupid places and then tipping them into the engine bay.
Daveperc wrote: Well done - did you work for Haynes??!!
Hehe. No. But I've used enough. And I hope this is clearer than most Haynes instructions which always seem to be missing vital stages.
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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RE: Re: RE: DIY spark plug change RS6 C5

Post by MartWilliams » Thu Oct 08, 2009 10:15 am

Excellent write up, great photos.

It is a bit of a daunting car for the DIYers out there, but it's still just nuts and bolts and stuff - at least in this case it is.

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Post by MartynC » Thu Oct 08, 2009 10:24 am

Well written and illustrated, many thanks.

MartynC

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Post by kwack » Thu Oct 08, 2009 10:30 am

The power of t'internet. I have learnt so much across many topics when enthusiasts have done picture "how to". This is excellent

Cheers

Kwack

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Shoppinit
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Re: RE: Re: RE: DIY spark plug change RS6 C5

Post by Shoppinit » Thu Oct 08, 2009 11:31 am

MartWilliams wrote:It is a bit of a daunting car for the DIYers out there, but it's still just nuts and bolts and stuff - at least in this case it is.
Definitely. Half the battle is getting over the fear! It's just a big V8 with lots of pipes and wires at the end of the day :)

I'd like to make this a sticky if there are no gross errors. Anyone know how to do this?
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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RE: Re: RE: Re: RE: DIY spark plug change RS6 C5

Post by posterboyj » Thu Oct 08, 2009 11:39 am

Impressive, good work shop
Cornishmoocher wrote:Buying an RS6 and then worrying about the fuel consumption is a bit like buying a boat and worrying about getting it wet.

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RE: Re: RE: Re: RE: DIY spark plug change RS6 C5

Post by spanner1210 » Thu Oct 08, 2009 1:51 pm

Shoppinit, you seem to know what your looking at under all the covers, is there any chance you could upload a phot of the engine with the various parts labled? like the dv's on this thread, just the main important stuff! Unless you know of a good link, I cant find anything!

Spanner
MUGELLO BLUE SALOON, 2004, STANDARD AT THE MOMENT

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Shoppinit
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RE: Re: RE: Re: RE: DIY spark plug change RS6 C5

Post by Shoppinit » Thu Oct 08, 2009 3:22 pm

I wish. I was just wondering what the thing was I had to move.
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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RE: Re: RE: Re: RE: DIY spark plug change RS6 C5

Post by mattler » Sun Oct 11, 2009 7:15 pm

Nice 1!!
Very helpful.

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RE: Re: RE: Re: RE: DIY spark plug change RS6 C5

Post by darrenswift » Sun Oct 11, 2009 10:10 pm

Extremely helpful, thanks very much.
If this could be made a sticky, as suggested above, it'd be most helpful for future reference.
Great pictures too.
Thanks for taking the time to do this :)
Daytona Grey Saloon | H&Rs | Phaeton Brake Ducts | MRC Gearbox Service | Plus Disks | Aluminium Trim | Massive Grin
"The early bird catches the worm, but the second mouse always gets the cheese!"

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RE: Re: RE: Re: RE: DIY spark plug change RS6 C5

Post by Shoppinit » Sun Oct 11, 2009 10:12 pm

My pleasure. I've tried what I can to make it a sticky, but there doesn't seem to be anyone at the helm of RS246.com...

Lights are on, but no one's home!
Daytona RS6 C5 Avant. Viper'd, Billies, Waggers, MTM box brain, C6 stoppers, xcarlink, R8 coolant cap (woohoo)
///M3 E46 | XC90 (V8, natch) | Passat GTE | RR Classic V8 flapper
"The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at and repair."

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Daveperc
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RE: Re: RE: Re: RE: DIY spark plug change RS6 C5

Post by Daveperc » Mon Oct 12, 2009 9:20 am

Try a PM to PhilT - I think he's still in charge!!

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RE: Re: RE: Re: RE: DIY spark plug change RS6 C5

Post by Cornishmoocher » Wed May 19, 2010 7:53 pm

I have just spotted this.

Great write up mate.

Mooch :thumb:
It's all Bollox.
Half of what you read is bull and the other half is all <beep>.

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