Glow Plugs
Glow Plugs
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Engine Bung Set (VAS 6122)
• Hose Clip Pliers (VAS 6362)
• Socket Insert AF 12 for Glow Plugs 4-Cyl. TDI CR (VAS 6454)
• Follow the safety precautions when working on the diesel direct injection system. Refer to => [ Safety Precautions ] Diesel Fuel Injection.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Diesel Fuel Injection.
Always follow these instructions before and during work.
Requirements:
• Ignition is turned off.
• Engine must be cold.
Removing
• When removing the glow plugs, make sure no contaminants enter the fuel system and the glow plug bore.
• Seal off the connections in the fuel system using plugs from the engine bung set (VAS 6122).
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the protective strip, if equipped.
- Disconnect the fuel injector connectors - A -, the exhaust pressure sensor 1 (G450) connector - B - and the fuel pressure sensor (G247) connector - C -.
- Remove the coolant line bolts - arrows - from the intake manifold and lay the line in front of the intake manifold.
- Remove the fuel return line bolt from the intake manifold.
Always follow the procedure "glow plug connector, disconnecting and connecting.
- Disconnect the glow plug connectors. Refer to => [ Glow Plug Connectors, Disconnecting and Connecting ] Glow Plug Connectors, Disconnecting and Connecting.
- Loosen the hose clip - arrow - using the hose clip pliers (VAS 6362) and remove the line from the fuel rail.
- Before removing, clean the return line connection on the fuel injectors (for example using a commercially available detergent).
- Dry the return line connections.
- Cover the return line connections with a cloth.
- Remove the fuel return line connections on the fuel injectors. Pull them upward to release them - arrow -.
• Maintain clean working conditions. Dirt and contaminants must not enter the return lines and the connections on the fuel injectors.
- Loosen the hose clip using the hose clip pliers (VAS 6362) and remove the fuel return line.
- Loosen the hose clip - 4 - using the hose clip pliers (VAS 6362) and remove the fuel return line from the high pressure fuel pump.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Remove the fuel return lines and lay them in front of the intake manifold.
- Remove the glow plug wiring guide and lay it aside.
• When cleaning the glow plug duct, make sure no contaminants or cleaning solutions enter the connector contacts on the glow plugs.
• Do not clean the connectors with cleaning solutions or compressed air.
- Clean the glow plug bore in the cylinder head (contaminants must not fall into the cylinder).
• Extract large contaminants with a vacuum cleaner.
• Clean glow plugs with a commercially available detergent.
• Dry the glow plugs with compressed air.
• Then clean the glow plug bore with a cloth dampened with oil.
- Remove the glow plugs using the socket insert AF 12 for glow plugs 4-Cyl. TDI CR (VAS 6454).
Installing
Install in reverse order of removal. When doing this note the following:
• When installing the glow plugs, make sure no contaminants enter the fuel system and the glow plug duct.
• Only remove the sealing plugs right before installing the fuel return lines.
• Make sure lines connections are securely fastened.
- Install the glow plugs using the socket insert AF 12 for glow plugs 4-Cyl. TDI CR (VAS 6454).
• Tightening specification: 12 Nm.
- Secure the fuel return line to the intake manifold.
• Tightening specification, see - item 3 - in => [ Fuel Rail and Injectors Overview ] Service and Repair.
- Connect the glow plug connectors. Refer to => [ Glow Plug Connectors, Disconnecting and Connecting ] Glow Plug Connectors, Disconnecting and Connecting.
- Read the Engine Control Module (ECM) Diagnostic Trouble Code (DTC) memory and erase all DTC entries. Refer to "Guided Functions" in the vehicle diagnostic tester.