Another bandwidth wasting glow plug issue....

[bootlegdsm]

OK, just to clarify since I'm one of the new guys. I've owned this car for 2 weeks or so. 85 Jetta TD

I have searched and read all the glow plug related stuff I could stand and haven't found what I was looking for. I have the easy 2 plug changed out already, but those 2 behind the injection pump are tricky to get at. Unfortunately my wrench is inadequately short for the job (my wife is pointing and laughing at me...I don't know why). I would like to know what tools you guys are using to remove these things without removing injections lines or anything.

[R.O.R-2.0]

remove the injection lines, it makes it much easier, and takes 2 minutes to get the lines off. then you can use an 8mm and 13mm? gear wrenches to take them out..

been a while since i did plugs.. cant remember what else its gonna take. it took me 30 mins to replace my glow plugs in my driveway..

[maxfax]

remove the injection lines, it makes it much easier, and takes 2 minutes to get the lines off.

X2..   The few mins it takes to pull those lines will save you an hour of agrivation...

[Vincent Waldon]

The other hint is that you may need to loosen the injection pump and rotate it forward so that the LDA (the spaceship thingie) moves out of the way a bit.

If you do this you'll want to scribe a pencil line between the pump body and bracket so that you can put the pump back where you found it.

[bootlegdsm]

Well I considered it, but I'm afraid of breaking stuff. I have a bad habit of being a little rough with things and costing myself alot of money. Small metal lines and me have had a few rounds in the past... thats why I asked. If I do try removing those last 2 lines to get at the plugs easier, whats involved in priming them?

[R.O.R-2.0]

put the lines back on the pump and crank till fuel comes out the injector end of the line..

then fire up the car.

[coke]

Its easier just to remove the whole assembly. They are 17mm nuts. They don't need to be super tight to not leak either. Just loosen all 8 with a 17mm wrench and spin them off by hand. I've had mine off half a dozen times or move over the years for various projects and maintenence.

When you put them back on to start the car, tighten the ones on the pump body to 18ft lbs or just "tight" but not too tight, and leave the ones on the injectors loose. Then get in, crank the engine over with the throttle to the floor till fuel is seen at all 4 injectors, tighten them up, glow the engine and start it.   You don't need your glow plugs to be on during the "fuel priming" so you can pull the fuse or relay, if you want to save on battery juice.

Trust me, its a LOT easier with the lines removed.

[bootlegdsm]

Great, I feel better about trying that now. Thanks alot guys. I have one more question, then I'm out the door, but I found the fusable link to the glowplugs was broken. I was going to replace it with a generic one, but I'm not sure on the amps... I think it's 60amp, is that correct?

[Vincent Waldon]

The stock fuse is 50A, but 60 is a better choice... if you can find it in that form-factor.

50A is right on the edge of the 48A the glow plugs draw normally... so over time the fuse tends to develop little micro-fractures all on its own.

[bootlegdsm]

Ok, so I did what you guys said. Yes, that is much easier. Still kind of a chore to get out but atleast it's possible. I was able to pull the last 2 between customers, hopefully finish it all up friday.

[Vincent Waldon]

It's a chore, but also the first of two important Rites of Passage.

If you can (a) change the glow plugs and (b) set the timing you instantly become am official VW Diesel Guru.. worthy of all praise and adoration therein.  

Your official Badge of Honour??  Skinned knuckles and the knowledge of several new swear words.   

[bootlegdsm]

Haha Thanks Vince, I guess I'm half way there then. The DSM's have already broken me in with skinned knuckles plus I can swear in 3 languages.

Thanks for the help ya'll... I appreciate it. I'll finish these things off this week, then I can move on to timing belt, valve adjustment, and then start modding a little bit.