Glow Plugs

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Torque Wrench (5-50 Nm) V.A.G 1331
Engine Bung Set VAS 6122
Hose Clip Pliers VAS 6362
Socket Insert AF 12 for Glow Plugs 4-Cyl. TDI CR VAS 6454

CAUTION:

Follow the safety precautions when working on the diesel direct injection system. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

Requirements

Ignition is turned off.
Engine must be cold.

Removing

NOTE:

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

Seal off the connections in the fuel system using plugs from the engine bung set VAS 6122.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the protective strip, if equipped.

-- Disconnect the fuel injector connectors -A-, the exhaust pressure sensor 1 -G450- connector -B- and the fuel pressure sensor -G247- connector -C-.

Fig 1: Identifying Fuel Injectors -A-, Exhaust Pressure Sensor 1 -G450- -B- And Fuel Pressure Sensor -G247- -C-

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-- 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 from the intake manifold.

CAUTION:

Always follow the procedure "glow plug connector, disconnecting and connecting.

-- Disconnect the glow plug connectors. Refer to GLOW PLUG CONNECTOR, DISCONNECTING AND CONNECTING .

-- Reposition the hose clamp -arrow- using the hose clip pliers VAS 6362 and remove the line from the fuel rail.

Fig 2: Identifying Hose Clamp -Arrow-

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-- Before removing, clean the return line connection on the fuel injectors (for example using a commercially available detergent).

-- Dry the return line connections.

-- Cover the return line connections with a cloth.

-- Remove the fuel return line connections on the fuel injectors. Pull them upward to release them -arrow-.

Fig 3: Identifying Direction To Remove Fuel Return Line Connections From Fuel Injectors

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NOTE:

Maintain clean working conditions. Dirt and contaminants must not enter the return lines and the connections on the fuel injectors.

-- Reposition the hose clamp using the hose clip pliers VAS 6362 and remove the fuel return line.

-- Reposition the hose clamp -4- using the hose clip pliers VAS 6362 and remove the fuel return line from the high pressure fuel pump.

Fig 4: Identifying Fuel Temperature Sensor -G81- Connector -1-, Fuel Metering Valve -N290- Connector -2- And Spring Clamps -3 / 4-

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

-- Remove the fuel return lines 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 bore, 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 bore in the cylinder head (contaminants must not fall into the cylinder).

NOTE:

Extract large contaminants with a vacuum cleaner.

Clean the glow plugs with a commercially available detergent.

Dry the glow plugs with compressed air.

Then clean the glow plug bore with a cloth dampened with oil.

-- Remove the glow plugs using the socket insert AF 12 for glow plugs 4-Cyl. TDI CR VAS 6454.

Installing

Install in reverse order of removal. When doing this note 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 right before installing the fuel return lines.
Make sure lines connections are securely fastened.

-- Install the glow plugs using the socket insert AF 12 for glow plugs 4-Cyl. TDI CR VAS 6454.

Tightening specification: 12 Nm.

-- Secure the fuel return line to the intake manifold.

Tightening specification, see -item 3- in the FUEL RAIL AND INJECTORS OVERVIEW .

-- Connect the glow plug connectors. Refer to GLOW PLUG CONNECTOR, DISCONNECTING AND CONNECTING .

-- Read the Engine Control Module (ECM) Diagnostic Trouble Code (DTC) memory and erase all DTC entries. Refer to "Guided Functions" in the vehicle diagnostic tester.