Glow Plugs

Glow Plugs

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Engine bung set (VAS 6122) (not illustrated)

• Spring-type clip pliers (VAS 6362)

• 15 mm socket (VAS 6454)

CAUTION!
• Follow the safety precautions when working on the diesel direct injection system. Refer to --> [ Safety Precautions ] Safety Precautions.

• Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.

Always follow these instructions before and during work.

Removing

Requirements

• Ignition switched off.

• Engine must be cold.

Procedure

• When removing the glow plugs, make sure no contaminants enter the fuel system and the glow plug duct.

• Seal the fuel system connections with sealing plugs from the engine bung set (VAS 6122).

- Remove the engine cover. Refer to --> [ Engine Cover ] Engine Cover.

- Remove protective strip --> [ 1 Protective Strip ] Removal and Replacement.

- Remove the connectors from the fuel injectors - A -, the exhaust pressure sensor 1 - B -, and the fuel pressure sensor - 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 --> [ 3 8 Nm ] Removal and Replacement on the intake manifold.

CAUTION!
Always follow the correct procedure for disconnecting the glow plug connectors!

- Remove the glow plug connectors. Refer to --> [ Glow Plug Connectors ] Glow Plug Connectors.

- Loosen the hose clip - arrow - with hose clip pliers (VAS 6362) and remove the line on the rail element (high pressure reservoir).





- Before removing, clean the return line connection on the fuel injectors with a commercially available detergent.

- Dry the return line connections.

- Cover the return line connections with a rag.

- Remove the fuel return line connections on the fuel injectors. Pull 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 with the hose clip pliers (VAS 6362) and remove the fuel return line --> [ 4 Fuel Return Line ] Removal and Replacement.

- Loosen the hose clip - 4 - with the hose clip pliers (VAS 6362) and remove the fuel return line at the high pressure fuel pump.





- Seal lines so that the fuel system is not contaminated by dirt, etc.

- Remove the fuel return lines --> [ 2 Fuel Return Lines ] Removal and Replacement and lay them in front of the intake manifold.

- Remove the glow plug wiring guide and lay it aside.

CAUTION!
• 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 duct in the cylinder head.

• Extract large contaminants with a vacuum cleaner.

• Clean the glow plugs with a commercially available detergent.

• Dry the glow plugs with compressed air.

• Clean the glow plug duct with a rag dampened with oil.

- Remove the glow plugs with 12 mm socket (VAS 6454).

Installing

Install in reverse order of removal, noting 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 immediately before installing the fuel return lines.

• Make sure the line connections are securely fastened.

- Install the glow plugs with the 12 mm socket (VAS 6454).

• Tightening specifications = 12 Nm.

- Secure the fuel return line on the intake manifold.

• Tightening specifications --> [ 3 8 Nm ] Removal and Replacement.

- Install the glow plug connectors. Refer to --> [ Glow Plug Connectors ] Glow Plug Connectors.

- Read the ECM DTC memory and erase all DTC entries.