Volkswagen Workshop Service and Repair Manuals

Removing and installing glow plugs Special tools and workshop equipment required

t  10 mm jointed spanner -3220-

t  Pliers -3314- »Carry out the following work sequence« Removing –  Switch off ignition. –  Remove engine cover panel → Chapter. –  Remove noise insulation at injectors. –  Clean glow plug channel in cylinder head; make sure no dirt gets into cylinder.   Note t  Cleaning procedure: t  Use a vacuum cleaner to remove coarse dirt. t  Spray brake cleaner or suitable cleaning agent into glow plug opening, let it work in briefly and blow out with compressed air. t  Then clean glow plug opening using a cloth moistened with oil.   Caution Make sure that no wiring connections are damaged when disconnecting the heater-element connectors. Otherwise the whole wiring harness will need to be renewed. Do not squeeze the pliers -3314- too firmly when pulling off glow plug connectors, because otherwise the support sleeve may be damaged.

–  Pull connector -B- off pressure differential sender -G 505- and fuel pressure sender -G 247--C-. –  Unscrew securing bolts (Golf, Golf Plus, Passat) of coolant line -arrows- from intake manifold and set line down in front of intake manifold.

–  Open cable guide fasteners, to free wiring harness.

–  Position pliers -3314- with groove -arrow A- on support sleeve shoulder -arrow B- and pull plugs off glow pin plugs.

–  Carefully pull connector off glow pin plug in direction of -arrow-.

–  Unscrew securing nut of fuel return line from intake manifold, open clamp -arrow- and pull line off high-pressure accumulator. –  Remove entire fuel return line and set it down in front of intake manifold.

–  To loosen glow plugs use special tool U/J extension and 10 mm socket -3220- Installing –  To tighten glow plugs use special tool U/J extension and 10 mm socket -3220- with a suitable torque wrench. –  Then tighten glow plugs to specified torque. t  Specified torque: 18 Nm –  Fit glow plug connectors onto glow plugs and ensure they are properly seated. –  Open cable guide fasteners to free wiring harness. –  Secure wiring harness in cable guide again. –  Further installation is carried out in the reverse order. –  Clear event memory of engine control unit.