Glow plug change

[ihs61]

Hi

I have a 2005 2.0 tdi 140bhp that I have been recommended to change the glow plugs on. (see my previous thred about smoking in the morning)

I have herd lots of horror stories about changing these ie snapping off etc.

Has anyone changed theres and if so can offer a few words of assistance about what the task entails.

Many thanks in advance

Ian

[arman123]

Hi

I have a 2005 2.0 tdi 140bhp that I have been recommended to change the glow plugs on. (see my previous thred about smoking in the morning)

I have herd lots of horror stories about changing these ie snapping off etc.

Has anyone changed theres and if so can offer a few words of assistance about what the task entails.

Many thanks in advance

Ian


before you take the glow plugs out make sure the engine is hot hot hot spray some plus gas on them leave for about 10 to 15 minutes then pray and try to undo them if they dont budge leave then more plus gas and try again good luck

[Alan02]

Also, if you do get them out, treat the new ones carefully as they are easily cracked, don`t fit if dropped ! Also bear in mind the low Torque value on fitting.

[Ben]

hi. did you get these changed? if so how much were you charged?

[ihs61]

Also, if you do get them out, treat the new ones carefully as they are easily cracked, don`t fit if dropped ! Also bear in mind the low Torque value on fitting.


As the weather got warmer the problem went away but I will get them done prior o next winter

Ian

[Ben]

I have an engine management light on, It starts and drives great. Ive had it diagnosed and it says glow plug on cylinder 3. Ive done some research and the glow plugs you need are specific to your engine code. Mine is a BRE in a 57 (2007) 2.0 A4 B7

I searched ebay and one seller included this link in their description NGK Partfinder (http://www.ngkpartfinder.co.uk/) which when i completed for my car NGK Partfinder for Cars & Light Commercial Vehicles (http://www.ngkpartfinder.co.uk/car_commercial_search.php?type=GLOW%2520PLUGS&manufact=AUDI&model=A4%2520%252804--%253E08%2529&engine=2.0)

gsf NGK GLOW PLUG 9835 180AA0300 (http://www.gsfcarparts.com/180aa0300)

euro http://www.eurocarparts.com/ecp/c/Audi_A4_2.0_2008/p/car-parts/car-service-parts/regular-service/glow-plugs/?438440186&1&5dbcf3a02188120a8e6d3dddb4311eb9adf67806&000164

and andrew page have a technical resource library that you can register free to use.

I dug this information out of a program i may have got off ebay

Different types of glow plugs
There are different types of glow plugs fitted in the 4-cylinder 2.0 ltr. 4-valve TDI engine in Audi A4 vehicles:
Engine code letters BLB, BNA
t These engines are fitted exclusively with metal glow plugs.
Engine code letters BRD, BRE, BRF, BVA, BVF, BVG
t These engines are fitted exclusively with NGK ceramic glow plugs, which are colour-coded with a “white, or possibly silver-coloured” seal.
Caution
Important: Always observe the special instructions for handling ceramic glow plugs. The metal glow plugs do not require any special handling procedures → Anchor.

Removing and installing ceramic glow plugs
Special tools and workshop equipment required

t Hand-held multimeter -V.A.G 1526C-

t Socket -T50001-
t Torque wrench
t Hose -N 020 150 05- approx. 250 mm long
Note the following points regarding ceramic glow plugs:
Caution
t Due to the special properties of the material used, ceramic glow plugs are easily damaged and require extra care when handling and removing/installing.
t Transport and store only in original packaging or packed separately in bubble wrap.
t Do not remove new ceramic glow plugs from packaging until they are ready to be fitted.
t Ceramic glow plugs are sensitive to knocks and bending. For this reason, ceramic glow plugs which have been dropped (even from a height of only about 2 cm) must not be installed, even if no damage is apparent (hair-line cracks may not be visible).
t Always install a new ceramic glow plug if you are not sure the old one is in perfect condition.
t Damaged glow plugs (e.g. heater pin of the glow plug is damaged) will invariably cause engine damage.
t If the heater pin of the glow plug is damaged, the fragments must be removed from the combustion chamber before starting the engine for the first time, otherwise this will invariably cause mechanical damage (piston seizure). If necessary, the cylinder head must be removed.
t To check compression, select function “Self-diagnosis compatible systems” in “Guided Fault Finding” (vehicle diagnosis, testing and information system -VAS 5051B-).
t The ceramic glow plugs must not be removed when checking cylinder compression.
t The software of the engine control unit is specifically adapted to either the ceramic or the metal glow plugs, so it is important to install the correct type.
t Mixed installation of ceramic glow plugs and metal glow plugs on the same engine is not permissible.
Removing
– Before removal, the ceramic glow plugs must be burnt clean using the “Final control diagnosis” function (vehicle diagnosis, testing and information system -VAS 5051B-).
– Remove cylinder head cover → Rep. Gr.15.
– Detach electrical connectors at glow plugs.
Caution
When loosening a ceramic glow plug, do not exceed the maximum release torque of 20 Nm. When loosening, always use socket -T50001- and a torque wrench.
– Carefully slacken glow plug. Do not exceed the maximum release torque of 20 Nm.
If the glow plug cannot be unscrewed with the maximum permitted torque of 20 Nm:
– Apply a suitable release agent (commercially available) and then try to unscrew the glow plug again.
Note
If it is still not possible to slacken the glow plug with the maximum release torque of 20 Nm after applying the release agent, remove the cylinder head and then unscrew the glow plug.
– Fit hose -N 020 150 05- (approx. 250 mm long) onto glow plug and unscrew glow plug, taking care to keep it straight.
– Carefully pull ceramic glow plug out from above using hose. Take care to prevent glow plug from contacting other parts.
Installing
Caution
t IMPORTANT: always observe the precautions listed above.
t The threads in the cylinder head and on the ceramic glow plugs must be dry, and free of oil and grease.
– Clean combustion deposits out of glow plug openings in cylinder head before installing glow plugs.
– Screw in ceramic glow plugs finger-tight.
Caution
It is most important to keep to the specified tightening torque for the glow plugs (threads dry, and free of oil and grease). The heater pins of the glow plugs can break if this torque setting is not observed, which would invariably cause engine damage.
Check function of ceramic glow plugs after installation and before starting engine for the first time.
– Connect multimeter (resistance test) to contact and body of glow plug.
l Specification: less than 1 Ω,
If specification is exceeded (resistance more than 1 Ω):
– Remove ceramic glow plug again and check whether the heater pin is broken.
Caution
If the heater pin is broken, the fragments must be completely removed from the combustion chamber before starting the engine for the first time, otherwise this will invariably cause mechanical damage (piston seizure). If necessary, the cylinder head must be removed.
– Re-attach electrical connectors, making sure that they are securely seated.
– Additionally check ceramic glow plugs via self-diagnosis vehicle diagnosis, testing and information system -VAS 5051B-.
1. Interrogate and erase fault memory of engine control unit. Do not start engine.
2. Perform final control diagnosis.
3. Interrogate fault memory of engine control unit once again. Do not start engine.
Note
The engine must not be started if the fault memory has registered a fault relating to the ceramic glow plugs.
– Check electrical wiring and connectors, make sure connectors are securely seated.
Tightening torque

Component Nm
Ceramic glow plug in cylinder head 8 … 11

[Crasher]

Those on the 2L 16v engine are always trouble free in my experience as they sit in oil all their service life. The worst ones are those on the V6 TDI's, one we did last year snapped all six!

[ihs61]

Good grief, I think I will buy a Morris Minor. Things were far simpler in those days !

[zollaf]

one of my customers did, got fed up of his corsa always having the em light on, so bought a moggy. hated it, always breaking down or just breaking, cold, slow, uncomfortable, noisy, poor brakes, in fact, poor everything, so bought a micra...

[ihs61]

My mother in law bought a Micra new back in 1993 and the bugger is still running and has only once let her down due to a dead battery, I wonder sometimes why the Japs lost the war !

[Crasher]

I wonder sometimes why the Japs lost the war !

Because the Americans dropped a couple of effing big bombs on them.......