Tips on changing a 1.9 TDi glow plug

[½cwt]

I've got an error code showing a problem with glow plug on cylinder 1 on a 1.9 TDi. Any tips on removing and refitting these?

I plan to test the resistance and see if it is to spec and if so clear the fault and then see if it reappears. If it does I'm then going to swap it over with one from another cylinder before paying out for a new one. I just need to know if it is straight forward or not.

[martin1810]

Disconnect battery, undo connections, unscrew plug. Take care with plug. Can be tight and you don't want one to snap. They are not that expensive. Why not just replace all four.

[tornadored7]

I've got an error code showing a problem with glow plug on cylinder 1 on a 1.9 TDi. Any tips on removing and refitting these?

I plan to test the resistance and see if it is to spec and if so clear the fault and then see if it reappears. If it does I'm then going to swap it over with one from another cylinder before paying out for a new one. I just need to know if it is straight forward or not.

Before condemning the Glow plug, use a multimeter to verify that the glow plug harness is operating correctly.

The following thread provides a useful heads up on Glow Plug removal issues (on an Audi A6, however the principles are similar);

Glow Plug Removal gone wrong...

Salient points raised are;

• Use a good penetrating fluid (Rost off plus is recommended by Crasher) every day for a fews days, prior to plug removal
• Thoroughly clean the area around the glow plug before plug removal, to prevent debris entering the cylinder
• To minimise the possibility of the glow plug shearing in the cylinder head, avoid reusing a used glow plug
• Torque the new glow plugs accurately to the correct setting/angle (15Nm ?). Do not over tighten.
• Above all, be patient!

Following Martin's advice, considering the risk:reward ratio of re-using a glow plug, I would consider this risky and not worth hazarding potential cylinder head work in the event of the glow plug shearing.

Regarding tools required;

• 10mm deep socket
• Universal joint
• Socket extension
• Torque wrench (~15Nm)
• Ratchet
• Multimeter (?)

TR7

[½cwt]

Got a price today of only £12.95 plus VAT for a new plug from VW, so as you say the costs makes it not worth messing around to try and make a saving.

[½cwt]

Just one thought, is it better done with the engine hot or cold, I'd guess hot if it is steel in alloy as the alloy expands more than the steel making the thread a less tight fit.

[tornadored7]

Just one thought, is it better done with the engine hot or cold, I'd guess hot if it is steel in alloy as the alloy expands more than the steel making the thread a less tight fit.

0.5cwt,

I've changed glow plugs on a hot engine for this reason, but curiously (in the previously referenced thread), Crasher mentions either hot or cold.

IIRC, ECP (Euro Car parts), quote somewhere in the region of £7.00 (ex vat) per glow plug for Beru (OEM) plugs, likewise GSF, but as you mentioned, plug re-use is not worth the considerable risk.

Best wishes and remember to be patient!
Regards,
TR7

[cazyp]

My local vw dealer charges £38+vat all in to replace all 4.
Now while there is some satisfaction in doing work yourself consider the cost of tools, the time and the risk of one sheering off. £44 well spent imho.

[passing]

Got a price today of only £12.95 plus VAT for a new plug from VW, so as you say the costs makes it not worth messing around to try and make a saving.

All four plugs replaced on my engine and at a cost of £8 each for NGK brand. Which makes the £40 odd quid for the ******* to do the job a real bargain. Mine charges a min 1 hr labour which plus parts trebles the cost above !

One thead stripped on removal of the old plug though so the tip to go with pentrating fluid first is I would suggest essential to avoid problems. You also need to move the fuel filter aside on an ATJ engine. The deep socket also means deep !
Good luck

[½cwt]

Just an update,

Did a resistance test across each plug, 3 showing 0.6 - 0.8 ohms, one, in cylinder 1 showing infinite resistance, so the error report was on the correct cylinder as a thread I looked at on TDI Forum for the error code (17055) indicated that sometimes the cylinders can be numbered or at least report in reverse order.
Old plug removed with no drama, just soaked the top of the thread with good old WD40 overnight. Fitted a single new plug from VW at about £14 incl VAT.
Thanks to all who contributed.

[jagerdan]

Hey guys,
Sorry to revive a very old thread but I'm looking at plugs on Ecp. There appears to be two different types/ lengths. Anyone know which ones I need for my 2004 A4 1.9tdi sport estate
Thanks in advance
Dan

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