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DIY Spark Plugs

163K views 269 replies 109 participants last post by  PuraVida  
#1 · (Edited by Moderator)
Hit 60k miles and finally got time for a spark plug change walk-through.
Before you start, I rate this a 2 out of 5 bloody knuckles. Its easy if you take your time, but a helping hand once in awhile will be beneficial. There are some not-so common tools required and I don't have "official" torque numbers or procedure from Porsche.

Total Time: 1.5 hrs taking it slow

Official torques from WM (2015 Turbo):
- spark plug, new - 25 Nm (tolerance +1.5 Nm), don't use lubricant
- spark plug, re-used - 31.5 Nm (tolerance +1.5 Nm), don't use lubricant
- fastening screw for ignition coil - 10Nm
- fastening screw for coolant reservoir - 5 Nm
- torque support pan-head aluminum screw - 20Nm + 180degrees - new screws must be used

Electrode gap - 0.8mm +/-0.05mm

Proceed at your own risk.
All torque values are estimated (by break-away, bolt size, or Bosch site)
I have personally removed head threads when removing spark plugs.
I have seen friends strip out threads when reinstalling spark plugs.
I have seen people drop screws through open spark plug holes.
The fix requires pulling a cylinder head which is $$$$$$.

Plugs:
Porsche Number: 999.170.233.90
Bosch Number: 0242245585 <---- Use this one to search.
Its an iridium plug with an odd electrode connection.
28 Nm tightening torque
0.700 mm gap (DO NOT STICK A FEELER GAUGE IN THE GAP)

Porsche Macan S Spark Plug

Required Tools:
E10 Female Torx
T-25 Male Torx (Star Drive)
T-45 Male Torx
16mm Shallow, Deep, AND/OR Box end wrench (if you only want it good-n-tight)
5/8" Spark Plug Socket (Its not a normal 5/8" deep well)
Short, Medium, and Long extensions
1 - 25Nm Torque Wrench
5 - 50Nm Torque Wrench

Optional:
Anti-sieze and die-electric grease

Start by opening your hood. If you can't figure that out......stop now.
Remove the top cover of the engine by pulling straight up in the front, then rear.
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Starting on the passenger side is easier and has more clearance. So you can get some practice in before tackling the driver rear cylinder.
Remove the engine air filter by loosening the 4 screws visible from the top. They are captured by the cover so don't get fully removed.
The cover pulls straight up for removal.
The side wall of the air box closest to the engine can the slide vertical. You will need to pull and shimmy a bit to removed it.
Once the side wall is removed, you can pull the filter towards the engine, then up.
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Next remove the two torx head fasteners that hold the wiring loom. No need to try and pry the wire loom open to unclip the coils.
With the wire harness fasteners removed, you can remove the coil connectors.
Push on the ribbed portion of the retention clip (center of connector towards the wires), while pulling the connector off the coil.
Resist pulling on the wires only, the connectors will come off with moderate force. Do NOT pry them off. You can do it with only your fingers.
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Next remove the anti-rotation link bolt that is attached to the valve cover. Notice the light torque on the nut.
Loosen the bolt on the other end of the link and swing it up and out of the way.
Image


Now you're free to remove the coils and replace the spark plugs. I do it cylinder by cylinder so that I don't mix coils (it doesn't matter).
Loosen the torx head bolt for the font cylinder coil. It is captured in the coil and can not be fully removed.
Pulling straight out (same angle as the head), pull the coil out of the spark plug hole.
Use a medium extension and spark plug socket remove the spark plug.
You should feel a soft torque break when first starting to loosen, then roughly 5nm resistance to finish threading out the plug.
With the plug out, verify you got the correct replacement plugs.
Verify the crush washer came out with the old plug.
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Reinstalling the Spark Plug
Torque per Bosch website: 28Nm
I used VERY light amount of anti-seize on the first couple of threads. Remember that anti-seize will modify your required plug torque.
I also added a bit of die-electric grease to the top of the plug for water intrusion protection. Some of the plugs already had it in the box.
Start the plug BY HAND and thread it until seated BY HAND.
If there is any question you cross threaded the plug, remove it 2 turns, then count 2 turns back in.
Torquing the plug up, you should feel a linear torque rise (crushing the washer and seating the plug) and then a rapid torque rise.
Once you hit the rapid torque rise, the plug will not turn more than 5 degrees before hitting the torque value.

Reinstall the coil pack and bolt.
Push in the center of the coil until it is fully seated on the spark plug.
Torque: <5nm

Continue on to complete the other cylinders on the passenger bank.
Reinstall the coil connectors by simply pushing the connector on until it clicks.
Wire loom bolt torque: <5nm

Reinstall the anti-rotation link to the engine.
Engine side bolt torque 15Nm
Frame side bolt torque 30 Nm


Reinstall the air filter, verify nothing got in on the clean side of the filter.
This is a good time to replace the air filters, although one of my new ones has some plastic flash in it.
Reinstall the air box wall by sliding it straight down.
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Drives Side
This side is a bit more tricky due to the coolant reservoir.
Remove the coolant purge valve from the air box side by sliding it forward and up. (No need to remove the screw)
Remove the drivers side filter and air box side, just like the passenger side.
Remove the two screws holding the coolant reservoir to the mounts. Note how the bottom has a tab and slot to guide it in place.
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Having a helper here will be beneficial to hold the coolant reservoir out of the way.
There are more hoses/wires on this side to contend with. Take your time.
Remove the two torx bolts that hold the wiring loom for the coils, then remove the coil connectors.
Image


Just like the passenger side, work your way from the front to the back changing the plugs.
When you get to the rear coil, the wire loom can be pushed towards the top of the engine, to get the coil out underneath.
You can then let the wires lay further down and work above them to remove/reinstall the spark plug.
Reassembly is like the passenger side. Be sure to get all of the coil connectors to "click" when pushing them on.

When done, start your car (hopefully) and check for error codes. If you do get a rough idle and a code, check the coil connectors first to verify they're seated. Then remove / reinstall coil packs to verify they're seated. If you still have a rough idle/missing cylinder. You'll need to pull and check your plugs. Its rare, but a bad spark plug out of the box is not unheard of.
@grim, could you sticky this. Thanks
 
#70 ·
20-22 ft-lb won't go wrong. Just make sure to work on cold engine.
 
#71 ·
I can confirm, the torque specs on the first post are exactly what I downloaded from the WM -

- New plugs 25 Nm tolerance + 1.5 Nm no lubricant
- Reused plug 31.5 Nm tolerance + 1.5 NM
- Fastening screw ignition coil 10 Nm
- Fastening screw coolant reservoir 5 Nm
- Torque support pan-head aluminum screw 20 Nm + 180 degree turn (requires new screws)
 
#172 ·
I can confirm, the torque specs on the first post are exactly what I downloaded from the WM -

  • New plugs 25 Nm tolerance + 1.5 Nm no lubricant
  • Reused plug 31.5 Nm tolerance + 1.5 NM
  • Fastening screw ignition coil 10 Nm
  • Fastening screw coolant reservoir 5 Nm
  • Torque support pan-head aluminum screw 20 Nm + 180 degree turn (requires new screws)
Anyone direct me to the correct pan-head aluminum screw? Where did you get yours?
 
#72 ·
As I recently purchased my CPO Macan GTS, I wanted to conduct a basic service on it to establish a baseline for future service. While the miles were fairly low for a 2-year old vehicle (just hit 22k), I am replacing some of the wear items now or within the next few months. I was going to change the spark plugs on my own but free time is becoming a rare commodity for me. Fast forward, the plugs were replaced this week by my selling dealer. Perhaps it's mental but the car does seem, if slightly, run smoother.

Photo of one of the original plugs. Though all six were in similar condition.
 

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#75 ·
...
Photo of one of the original plugs. Though all six were in similar condition.
I'm not an expert but, your old plug looks just fine to me.

Do you think the look of your old plug tells you it was time to change plugs? I don't.

Am I wrong?
 
#73 ·
So did we ever come to a consensus whether or not iridium plugs are the preferred/oem replacement? Im confused that the OP states:

"Plugs:
Porsche Number: 999.170.233.90
Bosch Number: 0242245585 <---- Use this one to search.
Its an iridium plug with an odd electrode connection.
28 Nm tightening torque
0.700 mm gap (DO NOT STICK A FEELER GAUGE IN THE GAP)"

But those part numbers lead to double platinum plugs? So for those who have pulled their plugs were they platinums or iridiums?

As an added question for those who have tuned with cobb etc... have you thought about or tried brisk silver racing plugs? Those are what I currently run on my tuned s4. TIA
 
#144 ·
So did we ever come to a consensus whether or not iridium plugs are the preferred/oem replacement? Im confused that the OP states:

"Plugs:
Porsche Number: 999.170.233.90
Bosch Number: 0242245585 <---- Use this one to search.
Its an iridium plug with an odd electrode connection.
28 Nm tightening torque
0.700 mm gap (DO NOT STICK A FEELER GAUGE IN THE GAP)"

But those part numbers lead to double platinum plugs? So for those who have pulled their plugs were they platinums or iridiums?

As an added question for those who have tuned with cobb etc... have you thought about or tried brisk silver racing plugs? Those are what I currently run on my tuned s4. TIA
Looking for the same info and couldn't find it going through the threads. So the plugs that come with the car are platinums or iridiums?

Thanks.
 
#74 ·
I ordered OEM plugs from Suncoast and they are platinum plugs. Iridium plugs have thinner center iridium tips.
 
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#78 ·
I plan to do both spark plugs and PDK fluid change at 40k miles.
 
#79 ·
Changed mine today.

Picked up the plugs from my local $tealership to aid in "documentation" of my self service. They looked good showing even burn across all 6 @ 30,400 miles on the clock.
 
#80 ·
Why don’t more people use FCPEuro? I have always used them, and living in MA/NH their free shipping option gets my orders here next day. Their prices are usually cheaper than everywhere else, if not about the same, but free lifetime warranty on everything from brakes to oil and filters, wipers, spark plugs everything. Buy a part install it, if it goes bad or is a wearable part, you buy new ones, have them ship the new ones to you, ship them the old ones and you get refunded. Yeah shipping cost, but save up for a big shipment and get a big refund. I send back pads, rotors, oil, plugs, wipers, fuel filters, coolant, water pumps, anything and everything. When I bought my CPO GTS I bought all oem Porsche filters, plugs, etc and it will be the last time I have to pay for them.

FCP is absolutely awesome.
 
#81 ·
How do they make money? I feel like ripping them off if I do that. They need to make a living too.
 
#82 ·
Over the years I have paid them a ton of money. They have been my go to for all vw/Audi/Porsche parts. I don’t get how they do it either, but they offer it and are very open about it. So for me it’s a no brainer. I use this for my personal cars only. I do have a shop and get almost all customer parts from them too, but that’s a whole separate account and I don’t do this with customer cars. I would assume they don’t even offer this to their commercial customers, have never asked.
 
#86 ·
I’m sure the rock auto plugs aren’t oem Porsche either, probably Bosch, which are same as oem, but at least I can have receipts for oem Porsche parts. And in that case, replace them once and you have hit the same price and then from then on they would be free.
 
#87 ·
I changed my plugs on Saturday using Suncoast parts. I changed them at 25K (yes, I know it's early). I read the forum's tips which were helpful. The entire job took 2.5 hours because I took it slow and had a few interruptions. The last 30 minutes were spent on the plug under the coolant reserve tank. Taking off that particular connector from the coil was a pain.

I have worked on cars for many years and although cars have become more complicated, forums like this make the job relatively straight forward. I appreciate the time people spent writing down their experience to help others.
 
#88 ·
Thanks for the great posts for DIY spark plug change!

I plan to change mine @ 30K miles. S/B ~4 ½ years.

Seems as though mijae28 used a regular 5/16 socket to remove wiring harness bolts instead of a E-10 female Torx. I do not have an E-10 female Torx socket (Or any Female Torx sockets)
I do have a regular 5/16 socket for my ¼ inch ratchet + a 3” extension + a ¼” torque wrench..
Will that be enough for all 6 wiring harness bolts?

I would hate to be in the middle of the spark plug job & discover I need to go & buy a tool.

I just bought the GEARWRENCH 80546 5/8-Inch x 6-Inch Swivel Spark Plug Socket recommended by shorton 335.
I also have a ⅝” ratchet & 3” & 6” extensions. {I need to buy a ⅝” torque wrench.}

I have male Torx bits; T-20,T-25, T-30 (& a T-40 which is not mentioned.)
I do not have a T-50 bit & think I need to buy one? Or should it be a T-45?

It is confusing to me that different people seem to be using different sizes of Torx bits.

Thanks!
 
#89 ·
You will need wobble extensions, rather than a swivel. The issue with the swivel is it allows too much play. I
completed the replacement job using wobble and/or straight 3/8" extensions. As far as the female Torx socket
goes, do yourself a favor and just buy one. I happened to have a couple of female Torx sockets on hand as
a result of having to pull a BMW transmission several years ago. Some of the bolts were accessible only by feel!

You have to get the wiring harness out of the way before you can loosen the Torx bolts for the coils, so no worry
about getting started and getting stuck.

The plug beneath the coolant expansion tank is really the only one that is moderately difficult. And with that one
you'll just need some way of keeping the tank elevated so you can access things beneath it (bolts, coil, plug).
One member mentioned using a bungee cord to hold it up. I ended up using a small block of wood. Getting the
coil 'tube' to release for that plug was an effort, again because of the limited space the ability to exert leverage
was compromised.

Just take your time.


Good luck!


;)
 
#91 ·
I bought the female Torx from Amazon. it is pretty cheap.
 
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#92 ·
Just did my 30K plug change today. With all the good info in this thread, once I dove in I felt like I had already done it before. Bigt thanks to TripleZ and to all others who have contributed.

For my part:

I am a tool junkie so I bought the specific VAG plug socket and extension called for in the WSM. Nice piece but not mandatory. As stated earlier in the thread, it's a real good idea to have an assortment of extensions in various lengths, wobble or otherwise, to make things go smoother.

I didn't have a bungee or an idle human nearby so I used a piece of twine to hold the coolant tank up and out of the way, which made access to the rear plug on the left cylinder bank much simpler.
 
#94 ·
Just an update on this thread to tell of my recent spark plug replacement on my 2015 Macan S. I did the replacement this weekend, early, at 28,900 miles. I bought the Bosch replacement plugs from Pelican at $11.75 each (total for all 6 = $70.50). It took me nearly three hours because I'm an old guy who works slowly and deliberately. Nothing too challenging, and less trouble to do than on my 996 Carrera.

However, I must say that I was surprised to find that the plugs that I took out, although somewhat discolored, as might be expected, did not show any discernible deterioration or erosion of either metal or ceramic and the gap measured at 0.7 mm, the same as the new ones.

What to think about this? Well, maybe my experience is an outlier, but it makes me skeptical that an owner needs to follow strictly the Porsche maintenance schedule for replacing spark plugs. I frequently push my Macan, do not baby it, but it was not misfiring before I replaced the plugs. Furthermore, I am running a COBB AP 91 octane OTS tune (love it!). Those are my variables.

My total cost to do this was a few hours of my time and less than $100. To hear that some Porsche dealerships are charging up to $600 for a spark plug replacement, and that some on this forum have said that they have even been pushed to replace coil packs at the same time (completely unnecessary unless one is failed), suggests to me that possibly unneeded maintenance schedules set by the manufacturer are huge money makers for the dealerships.

As a result of my experience, I will not continue to replace my spark plugs at intervals as short as 30K miles, but will extend it to at least 40K miles. This is an individual decision. Your mileage may vary.

:|
 
#95 ·
Good to know. I plan to do my plug change at 40k miles, at the same time of the PDK fluid change.

BTW, does the Cobb tune cause any shifting issues on your Macan S?
 
#99 ·
Thank you to all contributors. I‘m new to the Macan Forum and it has already been extremely helpful. Replaced spark plugs yesterday and only have three things to add that may be of help for others:

1) To remove the coils I used a nylon strap (3/4“ wide and very flat). After unclipping the coil fully removing the screw holding in the coil, there was enough play to wrap the strap under the coil head several times (choking it). This technique allowed me to easily pull out the coils (no bloody knuckles):
A) without removing the torque bracket on the passenger side (left hand drive)
B) by only elevating the coolant reservoir on the driver side (no need to disconnect hoses)
As a result of this relative easy removal of the coil packs, I opted not to use any baby powder when reinstalling them.

2) After removing the plugs and peering into the hole, I saw there was black dust at the base where the crush washer of the new plugs would seat. I didn‘t notice this until I was replacing the fourth plug. Ideally I‘d take some sort of a vacuum hose (diameter of a thick straw) and get rid of it. Since I don‘t have something like that, I tried using an extending magnet, but that was of limited use. In the end, I was able to remove about 50% of this „dust“. If you can figure out how to get it out, might be worth it.

3) I bought Genuine Porsche plugs from fcpeuro.com because their loyalty program is amazing; the next purchase of plugs gets fully reimbursed after I send them back the ones I purchased last week. Return shipping to them is my responsibility. I am not affiliated with fcpeuro nor have I had a chance to take advantage of their loyalty program, but they have been in business long enough and stream a live web cam of their warehouse receiving used wear & tear parts that get processed for reimbursement. Seemed like a no-brainer. I also bought their front and rear OEM brake replacement kit and will start tackling that project today.

Finally, be sure not to use a 27 torx driver on the 30 head. As a beginner, I grabbed the wrong torx driver and when torquing it down stripped it. At least it is in place, but now I have to replace the bolt somehow.
 
#100 ·
First I want to thank TripleZ for the write up and also everyone who has added comments. I changed my plugs today while watching the Cowboys get clobbered by the Patriots. With the write up and all the comments it felt like I had done this job before.
I purchased the Bosch 7432 from Rockauto.com for about $7.50 each.

The gearwrench spark plug socket seems like it’s made for this car. This with another short extension was perfect.
https://www.amazon.com/gp/product/B0014ZVSVK/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1

Below is a picture of the plugs that came out with 30,300 miles on them. I think they could easily go another 30K or more.

 
#102 ·
First I want to thank TripleZ for the write up and also everyone who has added comments. I changed my plugs today while watching the Cowboys get clobbered by the Patriots. With the write up and all the comments it felt like I had done this job before.
I purchased the Bosch 7432 from Rockauto.com for about $7.50 each.

The gearwrench spark plug socket seems like it’s made for this car. This with another short extension was perfect.
https://www.amazon.com/gp/product/B0014ZVSVK/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1

Below is a picture of the plugs that came out with 30,300 miles on them. I think they could easily go another 30K or more.

View attachment 227838
It seems every time I read this forum it costs me money. I had to go for the socket as it is so cool.
 
#101 ·
#103 ·
Kudos to TripleZ for the write-up. With the Gearwrench socket and the great tips here, it was a veritable "piece of cake". At 28,000 miles, I saw very little erosion on the old plugs. I did use a small amount of Copper anti-seize on the threads, a little Dielectric grease on the tips of the coil packs and some talcum powder on the friction surfaces where the coil packs enter the spark plug recesses. I saw no need to remove the engine brace...Plenty of room to get to that plug.
 
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