Glow Plug: Service and Repair

Ceramic Sheathed Element Glow Plugs

Special tools, testers and auxiliary items required

• Hinged Socket (3220)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Multi-Meter (V.A.G 1526 A)

• Connector Test Set (V.A.G 1594 C)

• Assembly Tool (T10410)

• 3 mm Diameter Rubber Hose, Commercially Available

Test Conditions:

• Engine is cold

• Ignition is turned off

Removing

• Observe the visual characteristics of ceramic sheathed element glow plugs. Refer to => [ Visual Characteristics of Ceramic Sheathed Element Glow Plugs ] Visual Characteristics of Ceramic Sheathed Element Glow Plugs.

• When removing and installing, do not tilt the ceramic sheathed element glow plugs. Remove components that are in the way.

- Remove the upper oil filter housing. Refer to => [ Oil Filter Housing Overview ] Description and Operation.

- Remove the coolant connection. Refer to => [ Coolant Connection ] Coolant Connection.

- Remove the by pass flap and the Exhaust Gas Recirculation (EGR) cooler. Refer to => [ Bypass Flap with EGR Cooler ] Service and Repair.

- Disconnect the connectors - A - from the glow plugs using the assembly tool (T10410).






- Remove the ceramic sheathed element glow plugs using the hinged socket (3220).

Installing

• Never oil or grease the threads of the bore in the cylinder head or on the ceramic sheathed element glow plugs.

• Clean the bore and the threads in the cylinder head thoroughly before installing.

- Install a 3 mm rubber hose on the glow plug and carefully install it as far as possible into the cylinder head.

- Tighten the glow plug using the hinged socket (3220). Tightening specification: 15 Nm


After installing and before the first engine start with a cold engine, perform a resistance test on all ceramic sheathed element glow plugs.

• Specified value: maximum 1.0 ohms

- If the specified value is exceeded, replace the malfunctioning ceramic sheathed element glow plug.

• If the malfunctioning ceramic sheathed element glow plug is broken, remove all broken pieces from the engine, otherwise they can cause damage to the engine.

- Attach the glow plug connector - A - using the assembly tool (T10410). Make sure it attaches correctly.






- Install the by pass flap and the EGR cooler. Refer to => [ Bypass Flap with EGR Cooler ] Service and Repair.

- Install the coolant connection. Refer to => [ Coolant Connection ] Coolant Connection.

- Install the upper oil filter housing. Refer to => [ Oil Filter Housing Overview ] Description and Operation.

- Fill the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.