TDI glowplug solution from TDi Club courtesy of Vince Waldon

[bbob203]

Since vince doesn't post here much anymore I figured i'd spread this since a lot folks here avoid TDi Club.

It will also take an 8-32 machine screw die, which might be a little easier to find hardware for in some locations:





In terms of the factory harness...there was a model change somewhere in the 2001-2002 timeframe where VW switched from 2-wire harnesses to 4-wire harnesses, in part to allow plug-specific diagnostics.  The old two-wire harness has been NLA for some time now, so anyone that repairs a 2-wire engine generally has to splice in the available 4-wire harness.

Or delete it entirely and run one's own wires...as heavy-duty as one's OCD requires.   :-)

[vanbcguy]

^^^^ Great idea

I'm definitely doing that. 

[homerj1]

Did this on my 1.6, combined with separate fuses for each glow plug and the results have been great.

[theman53]

The main difference is the 1.6 glow plugs are already threaded.

[bbob203]

I tried that on my mk2 but had issues with the fuse block being junk and just went to a single fuse coming off a starter solenoid. Going to wire my TDi glowplugs in series to a single 50 amp large maxi fuse to a solenoid. The TDi glow plugs are so easy to pull that I don't think individual is necessary except on the later ALH where they are wired individually from the harness. A 4mmx.7mm die also works to cut threads on the posts of the glow plugs as well.

[libbydiesel]

You could just use bullet connectors.

[bbob203]

You could just use bullet connectors.

I have messed around with those but I don't like them any of the ones I've found found deform when you put them on and take them off again and don't seem to keep a good connection. I cant find any in 12-10 ga wire. Cutting some threads will be a minimal task and a die only costs 4 dollars and will presumably last a lifetime.

[CRSMP5]

just rember your shifter when you goto cut threads... seen idi plugs breakj taking the nut off like your shifter did..

[8v-of-fury]

You could just use bullet connectors.

The Ford IDI IH late 6.9/7.3 were bullet style connectors. How often are you removing your glow plug harness? lol

[bajacalal]

You could just use bullet connectors.

The Ford IDI IH late 6.9/7.3 were bullet style connectors. How often are you removing your glow plug harness? lol

Those trucks have a huge issue with the connectors becoming loose, corroded, falling off and then the truck doesn't start. If you want one of those trucks I bet you could find one cheap right now that's it's getting colder usually with the phrase "ran great a month ago, can't get it to start anymore."

[vanbcguy]

Over on TDIClub you will find tons of posts from people with corroded / failed glow plug harnesses. That's why Vince posted that over there in the first place. The factory push on connection is less than reliable.

[Vincent Waldon]

WAY less than reliable, in my experience, hence good ole fashioned threads and nuts  rather than press-ons 

[bbob203]

Well i threaded a "stale" glowplug i had laying around no issue with dislocating the post its shank can be gripped with a pair of pliers to cut the threads. Debating on spade terminals or ring terminals.

[CRSMP5]

ring better then spade... and you figured out plier trick... just no break like shifter sir... you now know to support it..