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All in all it went well and Im so glad to have my 2000 D2 A8 running like a champ again. The transmission was in superb condition just as foreseen -- EH
    
Tech Article

Audi D2 A8 Spark Plug Removal and Replacement

Last Updated: 08/21/2018
   
Parts Group: Engine and ancillaries
This article discusses our internal notes for removing and replacing the spark plugs on an Audi D2 A8 or S8. The information herein is based on work I did on a 2003 D2 S8.

Have a degreasing agent, a shop vac, some non-frayed cotton cloths (such as handkerchiefs), paper towels, a magnetic pick-up tool and two cardboard boxes handy.

Prepare a box top to have eight numbered holes large enough to accept the coil packs. Use the convention whereby number 1 is closest to the passenger side from of the car, number 2 is slightly closer to the passenger while still on the passenger side of the car, and number 8 is closest to the steering wheel.

Prepare a box top to have eight numbered holes large enough to accept the spark plugs.

Use a medium-sized Philips screwdriver to remove the engine covers.

If you desire to clean the tops of the valve covers, this is the time. Use a degreasing agent.

Use a flat screwdriver to dramatically loosen the hose clamps on the air funnel from the air filter box to the throttle body. Detach the air funnel at the flexible section and then swivel the funnel up to clear the valve cover area.

Use a 10mm ¼” ratchet with shallow socket and medium extension to remove the two screws that attach each metal strip that forms the attachment point for the engine cover on that side. The passenger side has two holes to accommodate an engine cover; the driver side has three. Lift the strips away, while recording how they are positioned.

For each coil pack, push the wiring plug in towards the coil pack to reduce tension on the clip, then with the other hand push the clip (very near the edge) up and then while doing so, pull the plug away from the coil pack.

Use a 10mm ¼” ratchet with shallow socket, sometimes with a medium extension and sometimes not, to remove the two screws that attach each coil pack to the valve cover. Lift each coil pack out. Inspect it for oil contamination and a split bottom. Then, wipe it clean of oil, and place it in its hole in the box. Make a note of any problems observed.

If you desire to clean the tops of the valve cover rubbers that surround the spark plug tunnels, this is the time. Stuff a strong cotton cloth such as a handkerchief down the hole so as to prevent debris from falling inside. Then vacuum up any debris, and if needed wipe the rubber clean with a damp paper towel, then dry it. Stuff a reasonably clean cotton cloth down each hole, to clean out any oil coating the walls. Remove the cloth and vacuum out any debris.

Spark plug wrenches come in mainly two sizes; small and large, the smaller one being 5/8”. Use a 5/8” spark plug socket with a 3/8” drive to remove each spark plug. Lift each spark plug out. Inspect it for oil contamination and other damage. Do not wipe it clean. Place it in its hole in the box. Make a note of any problems observed.

Have eight of Bosch new spark plug type 7406. Remove each plug from its box and remove the protective cardboard tube. About mid-way along the thread, smear some anti-seize compound onto the spark plug thread, thin and about ¼” long. Avoid contamination of the compound onto the tip of the spark plug because the compound is liquid metal and it would materially change how the spark plug would behave from then on.

Replace any coil packs boots that have split ends. Maintaining the positioning of the originals, reinstall the coil packs and 10mm bolts on either side, and torque these to (I’m guessing) 5 ft lbs, which is 60 inch lbs. They are not under tension so very little torque is needed. Too much can strip the valve cover. Note that the #1 cylinder coil pack bolt also affixes a wiring harness anchor.

Reinstall the electrical plug on each coil pack. Also note that the #5 cylinder coil pack is upside down relative to the other ones on that side of the engine, specific to the position of the electrical plug.

Reattach the metal strip that forms the attachment point for the engine cover on each side. Torque the 10mm bolts to (I’m guessing) 5 ft lbs, which is 60 inch lbs. They are not under tension so very little torque is needed. Too much can strip the valve cover.

Reattach the engine covers.
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