GTV V6 spark plug change (How to guide)
I wanted to change the spark plugs on my 1999 GTV V6 but having read a few threads about what "a nightmare" it was I had put the job off and off. I had a bit of a poke about and thought that it would be a lot easier than people had made out. I set about the job and an hour after I started I had new plugs in the car and was ready to reassemble. I'd also been stopping to wash my hands and take pictures at various stages to compliment the written guide but I can't upload them as it says "file too large". If anyone can help me with that then please message me.
Standard alun keys set, socket set with plug socket, screw drivers, insulating tape and a pair of hose clip pliers. They cost £6 so get a pair. HOSE CLIP PLIERS for CLIC & CLIC R TYPE HOSE CLAMPS Heavy Duty by BERGEN TOOLS
I've written the instructions with front meaning the number plate end of the engine bay and back being the windscreen side. Left and right as you stand in front of the engine looking at it.
Ok so you have assembled the tools, opened the bonnet so here we go.
1. Throttle body, disconnect the rubber pipe and move it to one side.
Steps 2 to 6 are regarding the disconnection of the Plenum chamber (air box that the throttle body is bolted to).
2. Disconnect the three pipes on the rear on the right hand side, not too far from the throttle body.
3. Left hand top , unclip the black pipe and electrical wire from the black plastic retainer and move them to one side.
4. Black canister to the rear left, undo the two alum bolts and push the canister to the rear. Use your socket set to unbolt the 15cm support bar and remove.
5. Rear lower, undo and remove two alum bolts that secure the chamber to the engine, one each side.
6. Unclip the six air intake pipes at the plenum chamber end. No need to unclip them from the chrome pipe end. You'll notice that the jaws on the hose clip pliers have slightly different angle, if you get them around the right way they work a lot better!
7. Standing by the passenger side wheel, lean into the engine bay. Grip the throttle body and lift upwards and towards the rear. Whatever you do, do not poke, fiddle or otherwise interfere with the flapper valve in the throttle body. Just keep your fingers out of there! As you lift the aluminium Plenum chamber pipe will pop out of the six air intake boots. Congratulations you now have the plenum chamber and throttle body in your hands. You may want to cover the air intake pipe to stop debris going into the engine (sods law and all that).
8. At the front of the engine undo the four alum bolts that hold on the "Alfa Romeo" cover and remove it.
9. You now have six coil packs exposed, all held in place with four alum bolts. All alum bolts are have been the same size, not so difficult after all is it? Undo and remove the coil pack alum bolts. Be careful not to drop the two cable clips from the rear coil packs down the back of the engine. These are held in place by the alum bolts.
10. In the boot, disconnect the battery
11. You should be able to lift the three rear coil packs out as a unit without further dismantling, likewise the front three.
12. Remove the plugs, you'll need an extension bar.
13. Before putting the new plugs in use the insulating tape to secure your plug socket to your extension bar. You don't want the socket coming off and staying with the plug!
14. Putting everything back together is the reverse of above.
Note, refitting the plenum chamber can be a little awkward. I removed an engine breather pipe from just to the rear left of the plenum chamber and also the breather pipe union that is screwed into the engine. This did require a deep reach socket though, 25mm I think.
The only not standard tools were the hose clip pliers and the deep reach socket. I chose to spend far more time that it took to change the plugs on cleaning and repainting the plenum chamber, throttle body and front coil pack cover. Unfortunately I can't show the picture of that either.
I hope this helps, Brian.