02D2 Plug replacement

[cdodkin]

Read many articles in the archives about how difficult the plug change on the D1 is

Couldn't really find anything specific to D2 plug changing.

Is it the same as D1 - major plumbing removal required for access?

Going to be a fun weekend of fluid replenishment and general servicing in the D2, and I have the plugs in stock ready to go - so just seeing if I should plan to squeeze it in, or just stick to the diffs, trans, grease, nefr-bar fitting, PCV pipe replacement scheme?

Thanks for any heads-up.

Chris.

 

[andrewv]

Plugs are easy. Wires on a DII are what suck. Go ahead and do them, unless they're Bosch Platinums. Chris will let you know about that.

 

[Nori]

not to be rude, but :

open you hood and you will see.

 

[cdodkin]

not to be rude, but :

open you hood and you will see.

I would but the D2 is 500 miles away in AZ, and I'm in CA right now!

I need to be prepared for a busy weekend of servicing, and make sure I have everything ready to go after I've driven over there on Friday night!

Plugs I've obtained are the OE Champions - so should be good to go

 

[cdodkin]

Plugs are easy. Wires on a DII are what suck. Go ahead and do them, unless they're Bosch Platinums. Chris will let you know about that.

Is the problem that the wires break when you change plugs?

Should I be getting a spare set in stock now before I start the project?

Vehicle is at 55,000 miles, and has original wires (except for no7 which was swapped by the dealers a while back)

 

[Nori]

Sorry, yah, hard to see from 500 miles a way. even if you had good glasses.


If you are going to change the wires, YES it is a big time pain in the butt.
Even if your hands are small still its hard to reach in, since the connectors are right against the fire wall.
If you are just going to change the plugs, then you dont have to get a special tool to remove the wires.

 

[Plain2000DII]

Hijack On...

How hard is it really to change the plugs wires on a DII? I've read the miserable horror stories here, but ours REALLY needs a new set, I've just been reluctant to get started only to find it's near impossible. How about a straight up answer on this?

Hijack Off....

 

[WHM304]

I did the wires on my DII a few months ago. It is a big pain in the ass, but definatly possible. Not really technically difficult, but very cramped space between the motor and firewall. Do one wire at a time because it's hard to see back there and they could get mixed up. I found a long screwdriver was helpful to pop off the wires behind the motor.

 

[PolarG]

That is my next project and it looks like you will have to remove the upper inlet manifold. Seeing as how I could barely even see one of the boots on the coil packs, I can't imagine anybody being able to squeeze their hands back there, with the exception of a carny. I've never taken a manifold off before so I have no idea what condition the gasket will be in but the manual recommends changing that too (probably better to do it the first time than taking it off twice).
Let me know how that goes for you. I am a few weeks away from that project.

 

[WHM304]

I didn't have to take the intake manifold off. It probably would have made it easer but I didn't want to mess with it and didn't feel technically capable at the time. The way I did it was to take the hood off. With the engine cold i sat ontop of the engine, this way i was directly above the wires at the firewall. It is a tight squeeze but at that angle i was able to get my hand down in there. I know this seems strange but it worked for me and is a lot cheeper than the dealer.

 

[ptschram]

It does not require disassembly of the engine!!!

But, there is a reason book time is 1.7 hours.

 

[Nori]

ITs very hard. But I did it with my hands.
Along with lots of scraches to my hands, but still it worked.

 

[Plain2000DII]

Yeah, I'm trying desparetly to not go the "intake off" method, just seems to be alot of work for plugs wires. Can you actually see the coil pack? or is all this done by sight of hand? uhmm.. take the hood off...not a bad idea....

ps: hey look at me, one post from a hundred....hummm, gotta think of something..think man, think..

 

[Nori]

Just by the feel of your finger tips.
you realy cant see how it is. I also didnt want to take off the manifold.
So I printed out the wire directions, took off all the wires first and worked my self out from starting to put in the middle bottom ones in first and the top middle, bottom outer, then the top outer.

 

[ccdhowell]

I did wires two weekends ago, took me about 3 hours. Those things are a bitch and I have big hands. Found myself laying out across the engine and fenders with one hand trying to press the new wires back onto the coil packs. A screwdriver works great for taking the old ones off, but hands should be used to make sure the new wires lock into the coils.

It's tough, but at 76,000 miles my D2 really loves me now and revs much, much smoother too.

Plugs are a 20 minute job, no worries at all, easy on a D2.

 

[hywy61]

spark plug gaps

Stupid question here but how can i insure the gaps are correct. How do i adjust if not?

thanks.

 

[jsonova99]

Stupid question here but how can i insure the gaps are correct. How do i adjust if not?

thanks.

Go to Autozone or something and pick up a spark plug gap tool. They cost about a dime. Figure out the gap for the plug (I want to say 0.035, but that might be my boat) anyway, just slide the tool in and get to the right gap, if the gap is too small just bugger the tool along to bend the elctrode and if it is too big lightly press on a hard surface to bend it back.

My description is terrible, but when you see the tool you'll understand.

 

[WHM304]

I can't remember the gap setting off the top of my head, but i found it on a sticker under the hood above the radiator. seems like it was between 0.035-0.041. Hope that helps.

 

[bishop13]

Rave CD says .037 to .041

 

[deltadude388]

It does not require disassembly of the engine!!!

But, there is a reason book time is 1.7 hours.

just a thought, for 1.7hours, wouldn't it make sense to suck it up and let the dealer do it and save $$ on other easier DIY stuff? On mine, I can't see shit back there! let alone stick my fat fingers in it.