chris1972

My 3.0TDI is getting a little lumpy on start up and cranking couple more times than normal. I'm suspecting the glow plugs as there was an error code when it was remapped, which was for a glow plug.

Just wondering if this is a difficult job, where they are and how I access them. I can't seem to find any guides for replacing them.

I have a C6 A6 3.0TDI Quattro.

Any help?

Cheers
Chris

royclark

<TABLE cellSpacing=0 cellPadding=0 width="100%"><TBODY><TR><TD class=spalte-text><TABLE class="cc abstand-kap einzug-standard"><TBODY><TR><TD class=titel-kap>Removing and installing glow plugs</TD></TR></TBODY></TABLE>Note
<TABLE class="cc abstand-liste-erster einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Metal glow plugs are always fitted in the 2.7 ltr. common rail engine.





</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Two different types of glow plugs are fitted in the 3.0 ltr. common rail engine (engine code letters BMK and BNG): Bosch ceramic glow plugs or Beru metal glow plugs.





</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>It is very important to use the correct type of glow plugs depending on the software version of the engine control unit, otherwise the glow plugs will be irreparably damaged when the ignition is switched on.





</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard absatz-hervor"><TBODY><TR><TD>The following safety precautions are only required on 3.0 ltr. common rail engines with engine code letters BMK and BNG up to and including model year 2005.</TD></TR></TBODY></TABLE>






</TD><TD class=spalte-pfeil></TD><TD class=spalte-marg></TD></TR></TBODY></TABLE>
<TABLE class="cc einzug-standard abstand-standard absatz-hervor"><TBODY><TR><TD>Identifying the different types of glow plugs for the 3.0 ltr. common rail engine:</TD></TR></TBODY></TABLE><TABLE class="cc abstand-standard erlaeutrg-leg"><TBODY><TR><TD class=einzug-nummer>A - </TD><TD>Ceramic glow plugs are colour-coded with a „white seal“-arrow- and have a chamfered shoulder at the tip.</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste erlaeutrg-leg"><TBODY><TR><TD class=einzug-nummer>B - </TD><TD>Metal glow plugs are colour-coded with a „red seal“-arrow-.</TD></TR></TBODY></TABLE>



<TABLE class="cc einzug-standard abstand-standard absatz-hervor"><TBODY><TR><TD>Removing ceramic glow plugs (Bosch)</TD></TR></TBODY></TABLE><TABLE class="cc achtung-rahmen abstand-standard einzug-standard"><TBODY><TR><TD class=achtung-inhalt> Caution
<TABLE class="cc einzug-standard abstand-liste-erster achtung-rumpf"><TBODY><TR><TD>Due to the special properties of the material used, the ceramic glow plugs (Bosch type GSK3) are easily damaged and require extra care when handling and installing.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard achtung-rumpf"><TBODY><TR><TD>Always install a new ceramic glow plug if you are not sure the old one is in perfect condition.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard achtung-rumpf"><TBODY><TR><TD>If a ceramic glow plug has been damaged or the heater pin is broken, this will invariably cause engine damage.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard achtung-rumpf"><TBODY><TR><TD>If the heater pin of the glow plug is broken, the fragments must be removed from the engine before starting for the first time, otherwise this will cause mechanical damage (piston seizure). Remove the relevant cylinder head if necessary. </TD></TR></TBODY></TABLE>





</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Before removal, the ceramic glow plugs must be burnt clean using the final control diagnosis function in the diagnostic tester.</TD></TR></TBODY></TABLE>


Note
<TABLE class="cc abstand-liste-erster einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Wait for 60 seconds each time after performing final control diagnosis of glow period control unit. The ignition must remain switched on.





</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>If you do not wait for 60 seconds (if ignition is switched off and immediately switched on again), the glow plugs can be damaged (due to repeated pre-heating).




</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>The activation of the glow plugs is controlled according to coolant temperature.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Clean glow plug openings in cylinder head; make sure no dirt gets into cylinder.</TD></TR></TBODY></TABLE>


<TABLE cellSpacing=0 cellPadding=0 width="100%"><TBODY><TR><TD class=spalte-text> Note
<TABLE class="cc abstand-liste-erster einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Cleaning procedure:</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Use a vacuum cleaner to remove coarse dirt.</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Spray brake cleaner or suitable cleaning agent into glow plug openings, let it work in briefly, and blow out with compressed air.</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Then clean the glow plug openings using a cloth moistened with oil.</TD></TR></TBODY></TABLE>






</TD><TD class=spalte-pfeil></TD><TD class=spalte-marg></TD></TR></TBODY></TABLE><TABLE cellSpacing=0 cellPadding=0 width="100%"><TBODY><TR><TD class=spalte-text><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste></TD><TD>When loosening and tightening ceramic glow plugs, use special tool U/J extension and socket, 10 mm -3220- and a suitable torque wrench.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste></TD><TD>Unplug the connector from the glow plug to be removed.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste></TD><TD>When loosening a ceramic glow plug, do not exceed the „maximum release torque“ of 20 Nm. When loosening, always use U/J extension and socket, 10 mm -3220- and a torque wrench.</TD></TR></TBODY></TABLE>





</TD></TR></TBODY></TABLE>


Note
<TABLE class="cc abstand-liste-erster einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>If the ceramic glow plugs are difficult to remove (release torque more than 20 Nm), use a suitable penetrating oil spray and try again.</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>If one of the ceramic glow plugs cannot be loosened by applying the maximum release torque of 20 Nm, the cylinder head must first be removed so the glow plug can be unscrewed.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste></TD><TD>Then unscrew ceramic glow plug carefully by hand or using a suitable hose. Keep the glow plug straight while unscrewing.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste></TD><TD>Carefully pull ceramic glow plugs out from above using a suitable tool (such as a length of hose). Take care to prevent glow plugs from contacting other parts.





</TD></TR></TBODY></TABLE>
<TABLE class="cc einzug-standard abstand-standard absatz-hervor"><TBODY><TR><TD>Installing ceramic glow plugs</TD></TR></TBODY></TABLE><TABLE class="cc achtung-rahmen abstand-standard einzug-standard"><TBODY><TR><TD class=achtung-inhalt> Caution
<TABLE class="cc einzug-standard abstand-liste-erster achtung-rumpf"><TBODY><TR><TD>IMPORTANT: always observe the precautions listed above.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard achtung-rumpf"><TBODY><TR><TD>The threads in the cylinder head and on the ceramic glow plugs must be dry, and free of oil and grease.</TD></TR></TBODY></TABLE>





</TD></TR></TBODY></TABLE> Note
<TABLE class="cc abstand-liste-erster einzug-standard hinweis-rumpf"><TBODY><TR><TD>Before installing glow plugs, clean combustion deposits out of glow plug openings in cylinder head.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Screw in ceramic glow plugs finger-tight.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard absatz-hervor"><TBODY><TR><TD>It is important to keep to the specified tightening torque for glow plugs: „12 Nm“ (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 invariably causes engine damage.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Check function of ceramic glow plugs after installation and before starting engine for the first time.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD>After installation, check electrical resistance directly at glow plug contacts: not greater than 1 Ohm</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>If this specification is not obtained (resistance greater than 1 Ohm), remove defective ceramic glow plug again and check whether heater pin is broken. If a broken heater pin is visible, it is very important to remove the fragments from the engine before starting for the first time. Detach cylinder head if necessary; otherwise this will result in mechanical damage to the engine.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Reconnect electrical connectors on ceramic glow plugs. Make sure that connector engages properly.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD>Additionally check ceramic glow plugs via self-diagnosis.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Erase event memory of engine control unit. Do not start engine at this stage.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Perform final control diagnosis (automatic glow period control unit -J179-).</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Interrogate event memory again. Do not start engine at this stage.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>The engine must not be started if the event memory has registered a fault relating to the ceramic glow plugs. Check that electrical connectors have engaged properly.</TD></TR></TBODY></TABLE>


<TABLE cellSpacing=0 cellPadding=0 width="100%"><TBODY><TR><TD class=spalte-text><TABLE class="cc einzug-standard abstand-standard absatz-hervor"><TBODY><TR><TD>Removing metal glow plugs:</TD></TR></TBODY></TABLE><TABLE class="cc abstand-standard einzug-standard"><TBODY><TR><TD class=wz-liste-kopf>Special tools and workshop equipment required</TD></TR></TBODY></TABLE><TABLE class="cc abstand-standard einzug-standard "><TBODY><TR><TD class=einzug-liste>t </TD><TD>Torque wrench -V.A.G 1331-</TD></TR></TBODY></TABLE></TD><TD class=spalte-pfeil></TD><TD class=spalte-marg></TD></TR></TBODY></TABLE><TABLE cellSpacing=0 cellPadding=0 width="100%"><TBODY><TR><TD class=spalte-text><TABLE class="cc abstand-liste einzug-standard "><TBODY><TR><TD class=einzug-liste>t </TD><TD>U/J extension and socket, 10 mm -3220-</TD></TR></TBODY></TABLE></TD></TR></TBODY></TABLE>



Caution
<TABLE class="cc einzug-standard abstand-liste-erster achtung-rumpf"><TBODY><TR><TD>Mixed installation of ceramic glow plugs and metal glow plugs on the same engine is not permissible.</TD></TR></TBODY></TABLE>


<TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Switch off ignition.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Detach glow plug connectors from glow plugs which are to be removed.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Clean glow plug openings in cylinder head; make sure no dirt gets into cylinder.</TD></TR></TBODY></TABLE>


<TABLE cellSpacing=0 cellPadding=0 width="100%"><TBODY><TR><TD class=spalte-text> Note
<TABLE class="cc abstand-liste-erster einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Cleaning procedure:</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Use a vacuum cleaner to remove coarse dirt.</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Spray brake cleaner or suitable cleaning agent into glow plug apertures, let it work in briefly, and blow out with compressed air.</TD></TR></TBODY></TABLE><TABLE class="cc abstand-liste einzug-standard hinweis-rumpf"><TBODY><TR><TD class=einzug-liste></TD><TD>Then clean the glow plug openings using a cloth moistened with oil.</TD></TR></TBODY></TABLE>




</TD><TD class=spalte-pfeil></TD><TD class=spalte-marg></TD></TR></TBODY></TABLE><TABLE cellSpacing=0 cellPadding=0 width="100%"><TBODY><TR><TD class=spalte-text><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>To slacken the glow plugs use special tool U/J extension and socket, 10 mm -3220-.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Then unscrew glow plugs carefully by hand or using a suitable hose. Keep the glow plugs straight while unscrewing.</TD></TR></TBODY></TABLE></TD></TR></TBODY></TABLE>
<TABLE class="cc einzug-standard abstand-standard absatz-hervor"><TBODY><TR><TD>Installing metal glow plugs</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Before installing glow plugs, clean out combustion deposits from glow plug bores in cylinder head.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>To tighten the glow plugs use special tool U/J extension and socket, 10 mm -3220- with a suitable torque wrench.</TD></TR></TBODY></TABLE><TABLE class="cc einzug-standard abstand-standard "><TBODY><TR><TD class=einzug-liste>– </TD><TD>Then tighten glow plugs to specified torque.</TD></TR></TBODY></TABLE><TABLE class="cc abstand-standard einzug-standard "><TBODY><TR><TD class=einzug-liste></TD><TD>Tightening torque: 17 Nm</TD></TR></TBODY></TABLE>



Caution
<TABLE class="cc einzug-standard abstand-liste-erster achtung-rumpf"><TBODY><TR><TD>If the ceramic glow plugs (Bosch) have been replaced with metal glow plugs (Beru) the software of the engine control unit must be flashed accordingly before connecting the glow plug connectors. If this is not done, the metal glow plugs will be IRREPARABLY DAMAGED WHEN THE IGNITION IS SWITCHED ON.</TD></TR></TBODY></TABLE>

chris1972

Thanks for that... sounds a little precarious! Basically, I'd need to remove the glow plugs in order to ascertain which type they are by the colour coded seal or is this visible without doing that. Do I understand it correctly, in that I need access to diagnostics to fit them correctly? May be a job for the garage!

royclark

Colour coded seal is visible without removing them. The portion above the threaded part is outside of the head.

<TABLE class="cc einzug-standard abstand-standard absatz-hervor"><TBODY><TR><TD>Identifying the different types of glow plugs for the 3.0 ltr. common rail engine:</TD></TR></TBODY></TABLE>
<TABLE class="cc abstand-standard erlaeutrg-leg"><TBODY><TR><TD class=einzug-nummer>A - </TD><TD>Ceramic glow plugs are colour-coded with a „white seal“-arrow- and have a chamfered shoulder at the tip.</TD></TR></TBODY></TABLE>
<TABLE class="cc abstand-liste erlaeutrg-leg"><TBODY><TR><TD class=einzug-nummer>B - </TD><TD>Metal glow plugs are colour-coded with a „red seal“-arrow-.</TD></TR></TBODY></TABLE>



You will need access to diagnostics to fit them correctly.