Passat B6 2.0tdi Sport 2005, glowplug issues

[dutchy21uk]

Can someone shed some light on these issues!!!

1.Emissions workshop warning:

I have changed all 4 glowplugs due to code reader stated 2 glowplugs faulty.
1 week later its back again, lived with it but had the codes read recently and all 4 showing faulty!!!! :zx11: going to changed them again next week sometime but is their any suggestions!!! have been advised that the BKP engine glowplug wiring loom tends to rub on the head and short them, causing these to blow, but really all 4?????

2. Engine fault warning:

Now have this coming on, only after starting the car when the engine is warm, doesn't come on when cold!!! if it comes on and i key the car on and off quickly so the engine doesn't cut it stays off!!!!!

This is the only issue i have with this car, its a shame as its a great car and i don't want to get rid of it because its to tempermental!!!

Help please

[martin1810]

What code reader did you use and what codes did you get. What glowplugs did you fit. Only VW genuine ones or NGK are correct, you may have fitted the wrong ones, it does happen.

[dutchy21uk]

Thanks for your post, the codes were read by a VW, Audi specialist!!! so couldn't tell you!!! i installed 4 x Beru glowplugs given to me by a GSF dealer from my vin number :D but if thats right then NGK i'll need to get, any idea of the part numbers for the NGK etc!! is the YE14 right

Any idea on the second issue or could it be because all 4 showing gone!!!

thanks for your help!!!

[martin1810]

You used the wrong glowplugs. I hope you haven't blown the glowplug control module. Niether Bosch or Beru make glowplugs for the passat B6. As you have been running 4.5V glowplugs on a 7V system you may have just damaged the plugs.
NGK part No.s
BMP, BVD = CZ104
BKP, BMA, BMR, BWV, BVE, BUZ = CZ304
BLS, BXE, BKC = Y-607AS

[dutchy21uk]

Great, will get some this week, NGK all the way!!! i have searched the net for glowplugs for my BKP engine but they all come back as 4.4v with the NGK YE14!!!! just need to confirm the BKP 103kW 2.0 tdi engine is definately 7v 10mm glowplugs!!!

http://www.sparkplugs.co.uk/pages/pricing/ccp/glow-plugs/cross-ref.asp

this shows beru as spec for VW N10579802!!! am i looking at the right info etc.... thanks again

[martin1810]

If you do a search for NGK you can download their catalogue. If you check Beru website you will see they don't make glowplugs for a passat B6. Make sure you search PASSAT B6, not just engine code. When the same engine is fitted in different VW models, they use different glowplugs. So a 2.0 tdi can have different glowplugs in a golf compared to a passat.

[dutchy21uk]

Thanks Martin You've been a great Help, will let you know how it works out, have a great Day!!!!!!!

[dutchy21uk]

Well an update to this post, i have now installed 4 x CZ304 NGK 7v glowplugs but my warnings remain, is there a way to reset the fault codes without a VAG reader, also as the warnings are still on does that mean my control module is blown???

Any takers, please help

[martin1810]

VW warning codes don't reset. You need VCDS or a dealer to reset them. With luck that's all you need to do.

[dutchy21uk]

Martin,

Thanks fella, when i replaced the glowplugs with the wrong ones last-time the warning reset itself with a number of key on/offs.

Didn't work this time!!! also where is the control module situated, i have ordered one to be safe it arrives tomorrow.

Many thanks

Darren

[martin1810]

On left in engine bay near battery is E-box for engine fuses. Glow plug relay should be in the box underneath that one BUT on some cars it is on it's own clipped to the bulkhead in the same area. They changed it during 2005 !!!!!

[dutchy21uk]

Well, here is where i am, all 4 glowplugs replaced with NGK CZ304, new glowplug control module installed fault codes reset by garage, codes were as follows and what i think they are:

P0671 glowplug 1
P0672 glowplug 2
P0673 glowplug 3

Think i may have created these by disconnecting the battery:

19557 motor intake flap (i think this was me unplugging it when i removed the air intake)
0691 Fan 1. Control Circuit. Low
P2100 Throttle actuator control motor

and i still have the "Emission Workshop" illuminated and "Engine Fault Workshop"flashing!!!

I'm wondering if my wiring loom is suspect, does anyone know how i can test this loom in situ!!! pin out voltages etc or a guide :D

Starting to think i will never resolve this but also don't have much left to change so must be close!!!

Thanks for the help guys!!!!!

[martin1810]

19557 motor intake flap (i think this was me unplugging it when i removed the air intake)
0691 Fan 1. Control Circuit. Low
P2100 Throttle actuator control motor

This little lot usually mean the fuse has blown. The fuse changed during 2005. It should be in the E-box. (The one next to the battery) The fuse number varies with engine code so you will have to check them all. The fuse usually goes because the intake flap motor has failed. You might be lucky it might be just the fuse. Good luck

[dutchy21uk]

Well must be due some luck sometime soon. thanks again!!!

[dutchy21uk]

Martin, thanks for your sound advice, it was the fuse and my warning lights have now gone, i appreciate everything you have done!!!

Many thanks, just need to invest in vcds now ;-)

Take Care!!!

Darren

[martin1810]

Good news. Don't be tempted to go cheap with VCDS. Only buy the genuine thing. It will save you a fortune in the long run.

[vince47]

When I read the problems Passats have I get...
Depressed that my car might die in some expensive way, probably on my next trip!

Then I never fail to get impressed with Martin1810 and his detailed knowledge, this thread being a fine example.

Then I get depressed again when I see where Martin lives as its too far to go to get my car mended when it does die.
Anyway Martin1810, I am sure your updates are appreciated by many so keep it up, Vince:beerchug:

[fat controller]

When I read the problems Passats have I get...
Depressed that my car might die in some expensive way, probably on my next trip!

Then I never fail to get impressed with Martin1810 and his detailed knowledge, this thread being a fine example.

Then I get depressed again when I see where Martin lives as its too far to go to get my car mended when it does die.
Anyway Martin1810, I am sure your updates are appreciated by many so keep it up, Vince:beerchug:

Seconded - there are also others, such as Crasher for example, who are all invaluable to all of us.

I bought a car with a BKP engine before I read any of the woes on here, and must admit that I am nervous about what may lie in the future - however, it is good to know that there are good people, willing to share their knowledge and experience to help us get things sorted when it does all go wrong.

[dutchy21uk]

Vince,

Tell me about it!!! i am also wondering what my car will have in store for me in the future, its a great car and a damn shame it has so many underlying issues!!

But i suppose you have that will all cars and its better the devil you know than some japanese ***** ;-)

This forum is great and i agree its people like Martin and Crasher with their sound advice and experience that makes it that way!!!

Thanks to all!!! i'm sure i'll be posting something else in the future!!!

[billcoleman]

I just thought that I would share my glowplug experiences. I correctly diagnosed tha the "emmissions workshop" fault was due to a bad glowplug, so a new set was purchesed - but I recived the wrong ones (4.4v) even though I gave Euro Car Spares the correct car details. At that time I was unaware of the difference between the 4.4v and 7v items.

From the time I installed the plugs, the car did not run well, although the fault light was cleared. But eventually the fault light returned.

Thanks to this forum, I now have fitted the 7v glowplugs, and the car runs much moew smoothly - and no where near as much blue smoke on cold starting.

Now I just need to fin out how to remove the turbo to clean it to fix the "limp mode" problem. It looks to me like there is no room to get the thing out past the driveshaft.

[Phillemon]

Hi
I have replaced my glow plugs with bosch due to that emmision garage warning light and itwas still even after i have reset it with a vag and aweek later the car just stalled and does not not strart any more would think the problem might me the incorrect glow plugs?

Thanks in advanced

[martin1810]

You can't use bosch glowplugs in a 2.0 pd passat engine. They must be NGK or genuine VW. The glowplug controller under the E-box may well have been killed now.

[Phillemon]

:beerchug:Thank you very much martin1810 i will replace them and the controller and will let you know in about 4 days time.

God bless!!!!!!!

[Phillemon]

Please help :aargh4:

Where ist he glow plug relay located on Passat B6 20 TDI

Thanks

[martin1810]

It is under the e-box, under the bonnet. The black box with relays and fuses in. It slides out to the side from underneath. On some years it is a separate relay near the windscreen on it's own.

[Phillemon]

Thanks Martin18010 again for experties I managed to find the Glow plug controller unit and I ordered from the agency and I only got it today and fitted it but still it takes quite awhile to start and idles for a few second and it goes off so I was wondering if after fitting the relay does it need a reset or what else?

THANKS IN ADVANCE
Phillemon

[martin1810]

You can check out what is happening using VCDS for fault codes and engine measuring blocks to see what the glowplugs are doing. You will need someone with VCDS.

[Phillemon]

:beerchug:I would like thank all the people in this forum in taking their time in helping others specially martin1810 I finally got my Passat back on the road.The only problem that took longer was getting it the agent for reset .
The other challenge on they found out was tha my fuel pump in the the tank gave up aswell it also contibuted in the hard starting and short time idles.

Keep it up gentleman and best of luck!!!!!!!

[Zeb]

I received a code when I did a diagnostic check, on my Passat 2.0 TDI BKP. Code came out was, 17054 this suggested control moduling glowplug! I went to Euro car parts, and the cheapest in price were Denso for £60 a set. I know you mentioned (martin1810) that you will have to use NGK or VW plugs, but they are way too expensive. The cheapest NGK plugs I've seen online were £95 a set.

Is there any sponsers here, that can give me some discount?

[martin1810]

Are you sure Denso make glow plugs for a 2.0 pd passat. I am pretty sure they don't make them. If you fit the wrong ones it could prove expensive in the long run. Have you tested yours. They may not need replacing. Have a look here: https://sites.google.com/site/1810martin/passat-b6-glow-plugs

[vince47]

Are you sure Denso make glow plugs for a 2.0 pd passat. I am pretty sure they don't make them. [/URL]
Eurocar parts advertise Denso at
[url]http://www.eurocarparts.com/ecp/c/Volkswagen_Passat_2.0_2006/p/Car-Parts/Electrical-and-Lighting/Regular-Service/Glow-Plugs/?438440150&1&55ee5a6e862b866ae5606e43198b65e4e03636f4&GLOP (https://sites.google.com/site/1810martin/passat-b6-glow-plugs)
:confused: No certainty they are right though!

[Zeb]

Are you sure Denso make glow plugs for a 2.0 pd passat. I am pretty sure they don't make them. If you fit the wrong ones it could prove expensive in the long run. Have you tested yours. They may not need replacing. Have a look here: https://sites.google.com/site/1810martin/passat-b6-glow-plugs


I don't want to cause more damage to the engine, or find out that couple of 1K miles later the car starts to suffer! I have not tested it yet, the only reason I want to replace them, because everytime I scan the car that code comes up, and the car misfires just below 2000 rpm in 1st and 2nd gear.


Update: VW dealers are quoting me £94.38 for a set of 4.

Heres the link: Denso Plugs ~

http://www.eurocarparts.com/ecp/c/Volkswagen_Passat_2.0_2005/p/Car-Parts/car-service-parts/Regular-Service/glow-plugs/?438440150&1&55ee5a6e862b866ae5606e43198b65e4e03636f4&GLOP

[martin1810]

I am certain that Denso, Bosch and Beru DO NOT make glow plugs for the passat B6 2.0 pd tdi. I am happy to be proved wrong.

[dilun]

Just replaced my glow plugs again.last set only lasted 1 week.On removing the old set i found that they were berau 4.4v which i'm told are incorrect for the bkp. Having been quoted the best part of £100 by vw, i trawled ebay for ngk cz304. best buy was for audi a3 2.0 tdi and at £7.95 each and £2.75 delivery for 4 seemed very reasnoble.They seem to be working fine at the moment and my emission workshop error has canceled itself.Hoapfully its cured for now.

[Zeb]

Just replaced my glow plugs again.last set only lasted 1 week.On removing the old set i found that they were berau 4.4v which i'm told are incorrect for the bkp. Having been quoted the best part of £100 by vw i trold ebay for ngk cz304. best buy was for audi a3 2.0 tdi and at £7.95 each and £2.75 delivery for 4 seemed very reasnoble.They seem to be working fine at the moment and my emission workshop error has canceled itself.Hoapfully its cured for now.


Let me know how you get on! As mine recently comes up with Emissions garage! And still have the code whenever I plug in the vagcom machine. I too saw a set of CZ304 plugs, but they were for an udi A3 TDI, that's why I didn't go for them.

[martin1810]

All 2.0 passat engines (except BMP) use NGK CZ304 glow plugs. If you buy them from VW the VW box will have N 105 798 03 as the VW part number and the plugs inside will say NGK CZ304. They will be 7V. "£7.95 each and £2.75 delivery" is amazing as the retail price is £24 each.

[dilun]

Just to let everyone know,3 mnths on and the glow plugs seem to be holding out ok, turned out to be the cheapest repair i've done to the car.:approve:

[Warrenmole]

I also have the emission garage warning on my dash, was told by local garage it's showing fault in glowplug 2, so gonna try and get some, anyone any ideas of the cheapest place...don't fancy paying £100..also what would be the correct part number, as mine is a 55plate passat b6 2.0 tdi sport 140?? is it still the same as above..

[richball65]

Yeah Warren, it's the same NGK part number

[Warrenmole]

just scanned ebay, would this be the correct one for my car?? Are these easy to fit??

Item number: 350387502180 :confused:


Yeah Warren, it's the same NGK part number

[chudbug]

Hi all,Been lurking for a while to try and get to the bottom of my problem.Ive got a 2005 seat altea 2.0tdi with a similar problem to these on this thread .Scanned it and got these faults

g81 p0183 Fuel temp sensor a open or short to plus
cylinder 1 glow plug electrical fault p0671
cylinder 2 glow plug electrical fault p0672
cylinder 3 glow plug electrical fault p0673
motor for intake flap no signal v157 p3102
motor for intake flap open or short to ground p3101.

Ive checked the imf ,no stripped gears and functions fine (shuts after shutdown then opens again)
Egr valve removed and found with little soot and cleaned
All fuses removed and checked.also maf replaced
The eml comes on sometimes stays on then may go off for a few days then might comeback on again
Please help ! Im tearing my hair out with this light.:1zhelp:

[billcoleman]

just scanned ebay, would this be the correct one for my car?? Are these easy to fit??

Item number: 350387502180 :confused:

If your car has the BKP engine like mine, then I believe you need the 7volt CZ304 items with are about £22 each. i initially made the mistake of buying 4.4v items last year. They are fairly easy to fit, but you need to take the cam cover off to get to them (more difficult than some maintainance operations).

[chudbug]

Hi mate,yeah.couldnt find the glow plugs but now you say take the cam cover off that seems strange as it gets hot in there.That just means to me loom problems and crispy wires which could be casing these glow plug faults.Do you know of any probs with the glow plugs /harness or is the ecu just picking up the slow degradation of the plugs through the resistance value.Mine is the BKD engine which i think takes the 4.4v type
By the way,going to fit a new fuel temp sensor tonight .Hope this clears one fault.
Also do you know if the inlet motor flap( or throttle body as gsf call it )could be intermittent due to oil getting past the seals and chodding up the pcb inside?
Thanks for your previous reply

[billcoleman]

All the wires are splashed with oil and some people have had issues leading to replacement harnesses. Once you get the cover off, you can do a resistance check of each plug before taking them out.
My inlet motor flap failed completely - so I had to replace it with a new one. The old one was very clean, even though it is right next to the EGR valve (which gets quite dirty).

[chudbug]

Yep ,my one is like new also,i i think ill pick an imf up tonight as well .Cant believe a car with 35 k on the clock, 6 years old is causing this much aggro.Mind you it was aggro from the start,I had to have a new abs module fitted and programmed After 5 months -£1100 and two wheel bearings(under warranty thank god):p

[chudbug]

Update on the engine management light .I decided to start with the cheapest part then work my way up so tried the fuel temp sender/Sensor .So far after 4 days the light has stayed off . Got the vag com to do a readiness test and so far so good ,all egr and fuel systems are a pass.The glow plug faults are still there but it starts fine still.really happy its fixed but could not of done it without the obd scanner.Cheers guys for all your help .