Volkswagen Golf Workshop Service and Auto Repair Manuals

Removing and installing glow plugs, engine code CJAA Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331- t  Engine bung set -VAS 6122- (not shown)

t  Spring-type clip pliers -VAS 6362-

t  12 mm socket insert -VAS 6454-   DANGER! t  Observe safety precautions when working on diesel direct injection fuel system → Chapter. t  Observe rules for cleanliness → Chapter. Follow these instructions before starting work and while working on system. Removing   Note t  When removing the glow pin plug it is essential to ensure that no dirt enters the fuel system and the glow plug channel. t  Seal unions of fuel system with bungs from engine bung set -VAS 6122-. Prerequisites l  Ignition switched off. l  Engine must be cold. –  Remove engine cover panel → Chapter. –  Remove protective strip (if fitted) → Item.

–  Pull connectors off injectors -A-, exhaust gas pressure sensor 1 -G450--B- and fuel pressure sender -G247--C-. –  Unscrew securing bolts -arrows- of coolant line from intake manifold and set coolant line down in front of intake manifold.

–  Unscrew fuel return line securing bolt -arrow- from intake manifold.

–  Position groove -arrow A- in pliers -3314- over upper edge of connector -arrow B- and press lightly together.   Caution Position pliers so that it does not contact the cable or cause damage. Only use tool shown. Other, non-suitable tools may damage the connector. If the connector is damaged when pulling it off, renew the complete wiring harness including connector (an individual connector cannot be renewed).

–  Using pliers -3314-, carefully pull connector off glow plug in -direction of arrow-.   Caution Do not jerk connector off. The connector cable must not be damaged under any circumstances. Do not press pliers forcefully together, otherwise connector will be damaged. Connector is surrounded by a protective sleeve. If damaged, protective sleeve can be renewed.

–  Loosen spring-type clip -arrow- using spring-type clip pliers -VAS 6362- and pull line off rail element (high-pressure accumulator). –  Clean return line union on injectors to be removed (e.g. with commercial cleaning solution) before removing. –  Dry return line unions. –  Cover return line union with a cloth.

–  Pull off the connections of the fuel return line from the injector units. To release, pull upwards -arrow-.   Note Adhere strictly to rules of cleanliness. No dirt must be allowed to get into the disconnected fuel return lines or the open connections on the injectors. –  Loosen spring-type clip using spring-type clip pliers -VAS 6362- and pull off fuel return line → Item.

–  Loosen spring-type clip -4- using spring-type clip pliers -VAS 6362- and pull fuel return line off high-pressure fuel pump. –  Seal lines so that fuel system is not contaminated by dirt. –  Remove fuel return lines and set them down in front of intake manifold. –  Remove wiring from glow pin plugs and move it aside.   Caution t  Ensure when cleaning the channel for the glow pin plug that no dirt and no cleanser gets onto the contacts of the connector for the glow pin plug! t  Connector may not be cleaned using a cleaner or blown out using compressed air! –  Clean glow plug channel in cylinder head; make sure no dirt gets into cylinder.   Note t  Use a vacuum cleaner to remove coarse dirt. t  Clean glow plugs using commercially available cleaning solution. t  Dry off glow pin plug using compressed air. t  Then clean glow pin plug channel using a cloth moistened with oil. –  Remove glow pin plug using 12 mm socket insert -VAS 6454-. Installing Installation is performed in the reverse sequence. In the process, note the following: l  When installing the glow pin plug it is essential to ensure that no dirt enters the fuel system and the glow plug channel. l  Only remove sealing plugs immediately prior to installation of fuel return line. l  Ensure that line connections are tight. –  Tighten glow pin plug using 12 mm socket insert -VAS 6454-. l  Specified torque 12 Nm. –  Secure to fuel return line to intake manifold. l  Specified torque 8 Nm.

–  Guide centre contact -arrow A- onto connector on glow pin plug -arrow B-, by hand.

–  Push glow pin connector -1- on by hand until it audibly engages. –  Install fuel return lines. –  Read engine control unit event memory and clear all event entries → Vehicle diagnostic tester.