fitting glow plugs mk5 golf 2.0 gt tdi 140bhp

[willielavery]

Mk5 Golf 2004 2.0 ltr Gt Tdi 140bhp (engine slightly warmed up)

Remove plastic top cover ,one nut (10mm socket ) to rear left of cover then gently lift of with finger pressure.

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Unclip timing belt outer top cover, two clips to front then lift up and out of the way. remove with finger pressure.

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Unclip and remove rocker breather hose and disconnect air intake plastic pipe ( to rear right of engine) this is to give you room to maneouvre remaing plastic pipe behind the rocker.

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Remove the two silver bolts shown above (pipe mounting clamps) (10mm socket) remove all the rocker cover cover bolts (10mm socket) . These will remain attached to rocker once fully loosened. You may have to maneouvre silver pipes slightly out of the way to do this. Lift gently upwards and off takes bit of patience(moving up and gently to the right first worked for me)Take care not to force any tools under it to lever it off (rubber gasket underneath)You may have to maneouvre silver pipes slightly out of the way to do this.

Once in the oily bit you will notice a black plastic cable housing running right to left between the two cams. You should then notice four different coloured wires exit from the rear of it and under the rear cam. If you follow each one down to a small black plug, this is the electrical connection to the glow plugs. GENTLY lift this off and out of your way. Using an 8mm, long reach socket, on a 1/4 drive with short extension bar, remove/replace the glow plugs . I needed a 1/4 flexible adapter between the socket and extension bar to remove them, you may manage without .

Wipe clean the area were rocker gasket makes contact.

Refit/ replace is the reverse of the above.When refitting electrical contact to the top of the glow plug, locate correctly and push home "gently" you should feel it "grab" the top of a plug in the same way a plug lead does to a spark plug in a petrol engine. Have patience . Dont be tempted to overtighten anything, just exercise good judgement.. Dont turn on ignition until completely finished, this is just a precaution as vw's have a habit of throwing up error codes on their ecu.


Im not a mechanic , apologies for any poor description of parts or processes .This took me about an hour to replace all four and is working just fine.

Good luck and be patient and think of the money you are saving

[phil miller]

good write up but should be in the how to section, have you got anymore pics to help anyone trying to change them?

[willielavery]

Never took any more pics sadly, done in wet weather and getting dark. First attempt at a post for me will research how to post in correct area of forum. thanks for feedback
Regards

[onzarob]

You can't post directly into the 'how to' section. But I can move it for you

[golf+5]

Be Extra careful when you refit Glow plug.

Make sure that the Plug is perfectly aligned & only use gently finger pressure to start the thread.

Use 'Copaslip' on thread and torque to finally tighten.

(VCDS will tell which plug to change. Mine lasted between 4 & 5 years. I replaced with Bosch)

Also can check resistance with a ohm meter, will be less than 1 ohm if OK. Check before removing.

[Turbokiisseli]

Nice guide, but defo screams for pics!

New glow plugs will usually have a resistance of around 1 Ohm +/- 0.2Ohm. As long as all the plugs are in spec and don't differ from each other too much you're fine, but if one is showing infinite resistance or a much higher resistance than the others it should be replaced.

[willielavery]

Cheers -Added few more pics . Not Takin the rocker off again Tho , Scotia weather unpredictable at best !

[dem132]

I've changed over the my glow plugs in my BKD engine. The local VW specialist wanted £150 +VAT as its was pick up during it's 80K service, car's only a 06 plate and was 6 years old back in March. They gave me the VAG-COM report stating that 3 out of the 4 glows plugs had a fault but no warning lights tho?.
I wasn't having any of that! Using that foolish saying "How hard can it be!".
I agree with willielavery, patience is required when removing the rocker cover! The longest part of the job was taking off the rocker cover.
All done in hour and half.


The thread was missing a few pictures, so I'm taken those and hopefully help someone else out.


Picture of the rocker cover off.
Cover off.jpg
First glow plug picture.



Glow plug 1.jpg


I didn't have any deep sockets, trip to screwfix sorted that one. You require an 8mm deep socket, ideally with 1/4 drive as there isn't much space for anything bigger. Required a extensions as well.



Glow plug and tool.jpg

Hope this helps someone.

[dstephen82]

Excelent thread.
Do i need to replace the rubber gasket aswell?
Thanks

[willielavery]

Hope the guide and additions by fellow users helps you. Re the rubber rocker gasket, if you are careful not to tool it when leveraging up the rocker cover and it is not perished crackedor leaking then you shouldnt have to replace it.my golf had @80,000 on it when I did the job amd mines was as new. just be confident and patient. Good luck