Repair instructions
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        Power Unit
          DA-RM-05F001-01-001 - Remove/Install engine
          DA-RM-05F001-01-002 - Remove/Install front cover
          DA-RM-05F001-01-003 - Remove/Install NVH - Front Cover
          DA-RM-05F001-01-004 - Remove/Install perimeter seal - Front cover
          DA-RM-05F001-01-005 - Remove/Install seal - Crank - Front
          DA-RM-05F001-01-006 - Remove/Install seal - Crank - Rear
          DA-RM-05F001-01-007 - Remove/Install cylinder head assembly
          DA-RM-05F001-01-008 - Remove/Install camshaft cover - Left
          DA-RM-05F001-01-009 - Remove/Install camshaft cover - Right
          DA-RM-05F001-01-010 - Remove/Install chain drive kit - Camshaft
          DA-RM-05F001-01-011 - Remove/Install cam phaser - Left
          DA-RM-05F001-01-012 - Remove/Install cam phaser - Right
          DA-RM-05F001-01-013 - Remove/Install solenoid - Cam phaser - Exhaust
          DA-RM-05F001-01-014 - Remove/Install solenoid - Cam phaser - Inlet
          DA-RM-05F001-01-015 - Remove/Install sensor - Cam phaser
          DA-RM-05F001-01-016 - Remove/Install sensor - Cylinder head temperature
          DA-RM-05F001-01-017 - Remove/Install pressure switch - Oil
          DA-RM-05F001-01-018 - Remove/Install crankshaft damper
          DA-RM-05F001-01-019 - Remove/Install sensor - Crank position
          DA-RM-05F001-01-020 - Remove/Install sensor - Knock
          DA-RM-05F001-01-021 - Remove/Install thermostat assembly
          DA-RM-05F001-01-022 - Remove/Install hose - Degas
          DA-RM-05F001-01-023 - Remove/Install Assembly - Turbocharger
          DA-RM-05F001-01-024 - Remove/Install wastegate assembly - Turbo charger
          DA-RM-05F001-01-025 - Remove/Install dump valve
          DA-RM-05F001-01-026 - Remove/Install fuel rail
          DA-RM-05F001-01-027 - Remove/Install injector - Fuel rail
          DA-RM-05F001-01-028 - Remove/Install Intake manifold assembly
          DA-RM-05F001-01-029 - Remove/Install sensor - Temperature manifold absolute pressure (TMAP) - Intake
          DA-RM-05F001-01-030 - Remove/Install throttle body - Air intake
          DA-RM-05F001-01-031 - Remove/Install crank case ventilation (CCV) breather system
          DA-RM-05F001-01-032 - Remove/Install harness - Engine
          DA-RM-05F001-01-033- Remove/Install spark plug
          DA-RM-05F001-01-034 - Remove/Install Ignition coil
          DA-RM-05F001-01-035 - Remove/Install exhaust manifold
          DA-RM-05F001-01-036 - Remove/Install Hose - Water feed - Turbo
          GI-RM-0003 - Remove/Install Rocker mounting bracket
          GI-RM-0004 - Remove/Install Valve - Cylinder head
          GI-RM-0005 - Remove/Install Oil seal - Valve stem
          GI-RM-0006 - Remove/Install Ladderframe
          GI-RM-0007 - Remove/Install Camshafts
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Instructions
Powertrain / Engine / Power Unit / DA-RM-05F001-01-033- Remove/Install spark plug
Preparation work
1.     
2.     
3.     
4.     
5.     
6.     
7.     
DANGER!
 
Risk of death from high voltages in the ignition system!
Electronic ignition systems operate within a hazardous power range both at the low voltage side (primary circuit) as well as on the high voltage side (secondary circuit). Contacts with such parts can result in burns, heart flutter or cardiac arrest. Persons with heart pacemakers must not perform any work on the ignition system.
Wear safety shoes (with rubber soles).
•
Switch ignition off before commencing any work on the ignition system.
•
Do not touch or dismantle components of ignition system when working on running or rotating engine with cranking speed.
•
Detach the crankshaft position sensor connection either at the control unit or at the position sensor.
•
Do not install any electrically conducting, uninsulated adapters or installation sensors into the ignition cable.
 
WARNING!
 
Risk of burning and fire when handling hot or glowing objects!
Unprotected contact with hot or glowing objects can cause severe burns to the skin and eyes. If glowing objects come into contact with water, hot steam or hot splashing water this can result in severe skin and eye burns. Severe and possibly permanent injuries can result if hot or glowing objects come into contact with unprotected skin or eyes. Fire can result if glowing objects come into contact with flammable materials or substances.
Wear protective clothing, safety glasses and heat resistant gloves.
•
Avoid sparks and keep objects away from flammable materials and substances when handling glowing objects.
 
Remove spark plug
 
Care Point:
Allow vehicle to cool down sufficiently before carrying out any work.
 
1.  
Note overview of cylinder sequence 1 - 8.
 
2.   
 
Care Point:
Dependant on spark plug position, different tools should be used to aid removal.
Care Point:
For spark plugs in position 1 and 5 the following tools are required:
- Bent handle flexi head 3/8" drive ratchet with 6” locking extension.
- 14 mm spark plug socket that is either magnetic or has an interference fit.
For spark plugs in position 4 and 8, the following tools are required:
Bent handle flexi head 3/8" drive ratchet with 6” locking extension.
Universal joint.
2" locking extension.
14 mm spark plug socket that is either magnetic or has an interference fit.
For all the remaining 4 spark plugs, the following tools are required:
- Bent handle flexi head 3/8" drive ratchet with 2” locking extension.
- Universal joint
- 14mm spark plug socket that is either magnetic or has an interference fit
 
3.  
Remove spark plugs (1).18 Nm
 
4.  
Cover spark plug tubes (2).
 
Install spark plug
 
Care Point:
Make sure AV mount is tightened using the bottom hex head.
 
1.  
Replace ignition coil AV mount (3).
 
 
Care Point:
Do not attempt to use a spark plug that has been dropped or knocked, even if still in the packaging.
 
2.  
Check electrode distance (4) before you install the spark plugs (1). Electrode gap should be 0.7 mm.
 
3.  
Install components in reverse order.
 
4.  
Read out and clear error memory.
 
   
   
   Note