Spark Plugs on 1.4TSI 160HP

[Amith]

Hey there folks,

I am the proud owner of a 2009 1.4TSI 160HP but just as I hit 30,000kms, the misfire reared it's ugly head. The dealer couldn't fix it for the two times they looked at it so I am waiting to book it in at another dealership next week and maybe they can help.

What I want to do in the mean time is check the spark plugs. I need the following information if anyone can help.

I'm not new to car engines but this is the first modern car I have to look at for myself.

1. How do I get to the spark plugs, where are they?
2. What gap should there be? What does VW specify and has anyone had any experience with other gaps?

Thanks in advance,
Amith

[RW1]

They are under the top engine cover. Best lifting this off while the engine is still warm as the rubber grommets can tear when cold (Cost £4.75 each). Two studs near the front edge in either corner. Gentley pull the cover upwards about 5cm max. Then pull forward to release the rear centre stud which is in a horizontal slot.

You will now see the coil packs in front of you along the top of the engine. No. 2, 3 & 4 are easy to remove with the VW coil pack removal tool - T10094A (£35). Prising them out is not easy due to the tight fit and the grease applied during engine production at the factory. Also, damage may result to coil pack head using a screw driver or similar.

The T10094A tool with the T-bar handle is shown on the right hand side in the tray. Also in the tray is the Torx head drive, the removed Torx bolts for the oil breather and the 16mm spark plug socket with extension.

DSCN7906a.JPG

To remove the coil packs, once lifted about 1cm, unclip the connection to the wiring loom by stroking the connector's securing clip on the underside centre and then disconnect the loom connection by pulling and holding the underside clip open.

No.1 (nearest the right hand side of the Scirocco) is a little more difficult to remove. You will need to unbolt the oil breather pipe off the cam cover and some other attachments (two securing screws) to create space around No.1 coil pack. Then it can be removed with diffuculty using the VW coil pack tool.

This is how it looks with the engine cover removed and coil packs out. Where the orange dip stick handle is No.1 cylinder.

DSCN7907a.jpg

The plugs are deeply recessed in the head cam cover so you will need an extension bar.

Plugs are:ETA2: VW have officially recognised the 1.4TSi 160PS spark plug gap at 0.7mm .
Revised plug part number: (again!) 03C 905 601B.

Were: ETA1: 03C 905 601A has superceded (30.09.11) VW previous part 101 905 626 (old plug £12.35 each).

Torque : 25Nm
Plug gap 0.8mm to 0.9mm (31.5 thou - 35.5 thou)
Change interval : 60,000Km (37,000miles)

(NB: You have to be very careful re-gapping fine wire spark plugs that have very small diameter platinum or iridium alloy electrodes. Feeler gauges or wire gauges should be used with gentle care when testing the gap by comparing with the feeler gauage. Otherwise the central electrode tip will be damaged.).

I found both the factory fitted plugs and the VW spares were all over gapped to 38thou against above. This I shortened to 31 thou (about 0.79mm)and the engine has run very much smoother since for the last 3,000 miles. The exhaust tail pipes have gone from black and wet all the time to dry and a very dark slate gray. The engine pick up is better. And the very minor murmur of a misfiring stutter has gone.

C.

[martdy]

Excellent post as usually RW1 . Is it a similar process for the 2.0l Tsi ?
Cheers

[RW1]

2.0TSi Engine Cover will come off in a similar manner, do it while still warm so securing points are softer/more flexible.

Ignition coil pulling tool is different to 1.4TSi - need T40039 or similar. It slides onto the head of the coil packs. The slide puller fingers engage the coil head between the top "cap" and the first rib. Do not attempt to pull by engaging the puller's two finger slides below the first thin rib. This will cause damage.

T40039.JPG

2.0ltr & "R"
Plugs are VW part: 101 905 631H
Torque : 25Nm
Plug gap 1.0mm to 1.1mm (39.3 thou - 43.3 thou), Suggest gapping to 1.0mm - 39 thou.
"R" Plug gap 0.7mm to 0.8mm (25.5 thou - 31.5 thou)
Change interval : 90,000Km (56,000miles)
"R" Change interval : 60,000Km (37,000miles)

(NB: You have to be very careful re-gapping fine wire spark plugs that have very small diameter platinum or iridium alloy electrodes. Feeler gauges or wire gauges should be used with gentle care when testing the gap by comparing with the feeler gauage. Otherwise the central electrode tip will be damaged.).

"On the "R" only, the rubber mounts (4 off) of the engine cover are to be renewed each time the engine cover is removed. Also the intake has to be unclipped and a connection diconnected/the MAF unclipped on the righthand rear upper area.

C.

[martdy]

Thanks very much

[roccoSVK]

Let me know how all deal end up... having same problem with mine... spark plugs didnt solve it...

[Amith]

Hey roccoSVK,

They replaced the coil packs and updated the ECU software and all was sorted!

[ktmdave]

Also had the misfire problem on my Tsi, no 1 plug replaced.
Put the remap back on and its going like a boeing again.

Interestingly enough I had a 2.0 DSG as a loan car during the few days that VW were trying to sort my car out. Wanted to put an offer in to buy it, but my common sense got the better of me. - my comments are======>
-Dyna audio definately not worth the money (actually sounded worse than mine (I have the RCD 510 in mine)
-DSG - really great in traffic, and acceleration great, takes getting used too, pull away as smooth as hell, dificult to take a gap in trafffic as you do not know what the gearbox is going to do.
Brown leather seats felt more upmarket than my all black leather interior - but that could have been the sun-roof and extra light.
With the remap on the 1.4 the power is as close to the 2.0 as it gets but the 1.4 pulls better from low down.
Next car is going to be a CC

[tmeypaz]

Hi,
Sorry to bring this post from the dead but I'm experiencing similar problems and I need some advice.
I've been having my 1.4 160 for more than three years and 67,000 Km
2.5 years ago I've installed REVO stage 1 with 18,000 Km on.
On 60,000 service the spark plugs were replaced and on 63,000 Km it all started.
At first it was occasional mild and short hesitation and then it gradually grew to brutal hick-ups with engine fault indicator light for a few seconds each time.
When in idle the engine runs smooth with no indication of a problem.
I may be mistaking here but it seems that the probability for a hick-up when the engine is cold was much lower.

The log indicated misfire on cylinder 1.
Plug No 1 was replaced but it didn't solve the problem completely and provided merely a temporary relief
After a couple of days I returned to the shop where this time the log showed misfire in cylinder 1 and 4.
This time they replaced all four plugs and it seemed to have solve the problem, at least for a while.
After a few weeks I started noticing occasional hesitations but it's not as severe as it was when I got to the shop at the first time.

As you can understand I've been running more than 3,000K with the new plugs and I'm wondering if I should try replacing the plugs.
Can I get a recommended PN for a plug?

Cheers

[RW1]

Similar problem I had with a pre 24s4 VW map. That is, misfires jumping from one to other cylinders for no apparent reason. That lead to the spark plug gap investigations and now been running since September 2010 with 0.75mm (29 thou) gap with no further problems. Really smooth engine as a result.

The correct VW plug is now spark plug VW part number 03C 905 601A same as NGK PZFR6R8EG. Gapped at 0.8mm.

Revo recommend with Revo stage 1 - NGK BKR7EIX which is one step down cooler in the NGK plug heat range. Gapped at 0.8mm
(Don't buy NGK BKR7EIX-11 as these are gapped at 1.10mm!)

The plugs not to put in are 101 905 626 gapped at 0.9 - 0.92mm. Maybe they have fitted these. These are gapped too wide, 0.9mm is considered wornout by VW. And mine certainly were misfiring with the gap at this setting.

The original misfire in No.1 may simply have been the plug wearing, given the 60,000 km they had done.

C.

[tmeypaz]

The problems started only after the plug change at 60k. Actually at 63 to be precise.
I guess i was running with 0.8 as originals from 2009 with no problems and the new ones were 0.9 and that`s when the problems started.

This info is very helpful, I`ll give it a try.

Thanks

[tmeypaz]

Update:
I've been running for almost 3000K with 7EIX and it seems that the problems are gone.
No hesitations though I'm wondering if the fuel consumption is slightly higher or the smooth engine got me a bit more eager.
The gap is too small to know for sure. I guess time will tell.

Thanks a lot for your help.

[RW1]

I'm wondering if the fuel consumption is slightly higher

My records showed no change after reducing the plug gap (over 15,000Km), initially 0.8mm, now set to 0.7mm. I have done further work with the Camshaft Adjuster Solenoid Valve which has given a 5% to 8% improvement recently.

C.

[sciroccotunisia]

Thanks very much for all this very useful info.

I am planning to change the spark plugs of my 2010 Scirocco 1.4 tsi 160.
I have looked all over the web to find the VW 03C 905 601A / NGK PZFR6R8EG that you recommend. I found them nowhere, any idea where I can buy these on the web?

If I cant find them, what do you think of these 2 alternatives:
- I found these Bosch FR6HI332 which seem to have the right gap (0.8mm).
- You say revo recommend the NGK BKR7EIX which seem to be 1 level "colder" than stock, so what about : BKR6EIX which have the same heat grade and a 0.8 gap ?

Help and thoughts welcome! Thanks a lot!

[RW1]

VW have officially recognised the 1.4TSi 160PS spark plug gap at 0.7mm .
Revised plug part number: (again!) 03C 905 601B.

C.

[Rawcpoppa]

Great news. Did you get this from a tpi in Elsa or is it just listed as a new part in etka?


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[RW1]

Internal test data.

C.

[gkatsi]

Acording to the photo above, VW has changed the spark plugs from platinum to iridium but the gap remains the same, 0.8mm.

What am i missing here?

[RW1]

The setting is now 0.7mm - 0.8mm. So the plugs are 0.8mm by supply but the gap setting now goes down to 0.7mm

C.

[tmeypaz]

The gap went back to 0.8 from 0.9.