Volkswagen Workshop Service and Repair Manuals

Removing, installing and checking glow plugs Special tools and workshop equipment required

t  10 mm jointed spanner -3220-

t  Pliers -3314- Checking The glow plug system is monitored by the engine control unit's self-diagnosis system. The necessary checks are performed with Guided event finding. 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 Ensure that no cable connection is damaged when disconnecting the glow plug connectors, as the entire wiring harness must otherwise 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 off connectors -1+2-. 1 -  Differential pressure sender -G505- 2 -  Fuel pressure sender -G247- –  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 plug in direction of -arrow-.

–  Unscrew securing nut of fuel return line from intake manifold, open clamp -arrow- and pull line off fuel rail (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.