BEW Glow Plugs - help me figure out which ones I have?

[Concat]

Hello all,

Glow Plug on cylinder 2 is toast, but with the recalls I don't know which glow plugs I need to replace it with.

The dealership told me I have one outstanding recall which is related to glowplugs, and the only recalls I've had done are the Diesel pump kit and Brake light switch. If I have the original ceramic GPs, would they still have an open recall for my vehicle?

The fact that I have an outstanding recall makes it sound like I currently have steel GPs. But if the only recalls I've had done are the Diesel pump kit and Brake light switch, well then that sounds like I have the original ceramic plugs.

I have a VCDS; Is there an easy way to confirm using it?

Note that I do have a Kerma tune... so I don't want to get the recall done and pay for a retune as well. And Im hesitant to pull the glowplug without having a replacement on hand.

As always, thanks so much.

 

[boertje]

To be sure i think you would have to pull that plug and read the numbers off it. Thats what i did on mine and then order the updated plugs. If they are the original 7v plugs, iirc, the updated replacements would be N 105 916 09 or NGK CZ112. I found reasonable priced ones on fleabay.

 

[PakProtector]

I have to jump in with this, 'the glowplug is no proof of the ECU settings controlling its voltage'. So to say, you could have a 7V flash, and 7V plugs, or a 5V flash and 5V plugs...or any combination. I don't recall what VCDS reads with a tune, or what flavour of tune you have...I put a 7V engine into a 5V car and it started just fine... I ran out of winter before swapping 5V plugs in...

Look up a post by Franko6( or is it Frank06?), as he specifies maximum torque to apply whilst removing. You do not want to break one. Not even a little.

Douglas

 

[BobnOH]

And if they are the originals consider buying 4. Look into having the recall done, if of course if it won't affect your tune.

 

[Concat]

I have to jump in with this, 'the glowplug is no proof of the ECU settings controlling its voltage'. So to say, you could have a 7V flash, and 7V plugs, or a 5V flash and 5V plugs...or any combination. I don't recall what VCDS reads with a tune, or what flavour of tune you have...I put a 7V engine into a 5V car and it started just fine... I ran out of winter before swapping 5V plugs in...

Look up a post by Franko6( or is it Frank06?), as he specifies maximum torque to apply whilst removing. You do not want to break one. Not even a little.

Douglas

Thanks. I was just reading that:

according to Beru (one of the two OEM manufacturers of glow plugs for that era VW), they'll break at 35 NM (25.795 Ft*Lbs) torque

Also, I read that with VCDS you can check the ECU flash version, which will tell you if the recalls were done. 1386 for 5 volt plugs and 0282 for 7 volt.

Mine is 6110... So maybe that means I have the original 7v?

 

[Concat]

And if they are the originals consider buying 4. Look into having the recall done, if of course if it won't affect your tune.

The recall specifically mentions it will overwrite a custom tune...
The voltages and/or durations are changed as part of recall.

 

[BobnOH]

Try kerma for a little help, they should be able to tell you what's in the ECU

 

[P2B]

I recall @oilhammer posting a list of software versions and corresponding TSBs (there were more than just the glow plug revisions) but darned if I can find it now. Maybe he will see this and repost it.

 

[mjydrafter]

You can pull the bad one, read it (post #2), put it back in so she'll run, and get the correct replacement. Since it's summer, you should be okay for a bit.

If what you have works/worked, I would just replace with like and not open the BEW GP can o' worms.

Signed, a guy with at least 3 sets of BEW plugs... (I had the tuner make sure everything matched up to what I have in there now) IIRC they are the 7v NGKs)

 

[BobnOH]

I recall @oilhammer posting a list of software versions and corresponding TSBs (there were more than just the glow plug revisions) but darned if I can find it now. Maybe he will see this and repost it.

PD glow plug reflash dealer info

I am starting this thread as a way for anyone needing their BEW, BHW, or BKW engine's glow plugs replaced and the ECU reflashed at a dealership. DOES NOT APPLY TO ANY OTHER TDI ENGINES SOLD IN NORTH AMERICA EXCEPT THOSE THREE LISTED!!!! It would seem many of the dealer service departments are...

forums.tdiclub.com

The TSBs show the software versions.

 

[P2B]

PD glow plug reflash dealer info

I am starting this thread as a way for anyone needing their BEW, BHW, or BKW engine's glow plugs replaced and the ECU reflashed at a dealership. DOES NOT APPLY TO ANY OTHER TDI ENGINES SOLD IN NORTH AMERICA EXCEPT THOSE THREE LISTED!!!! It would seem many of the dealer service departments are...

forums.tdiclub.com

The TSBs show the software versions.

Nope, that 15 year old thread discussing the first recall is not what I was referring to.

 

[JB05]

I thought maybe MOGolf had a thread regarding the different software versions.

 

[P2B]

I recall @oilhammer posting a list of software versions and corresponding TSBs (there were more than just the glow plug revisions) but darned if I can find it now. Maybe he will see this and repost it.

Found it

2.5 Volts at glow plugs?

Wife's 2005 Passat TDI. Damn thing has been incredibly difficult to get started this past week due to near zero F temps. Finally, today was a little warmer so I got around to changing the oil and trying to figure out the glow plugs. Each plug showed battery voltage with my multimeter between...

forums.tdiclub.com

That and the next few posts in that thread.

 

[Matt-98AHU]

You can also tell what software your ECU has with VCDS. When you first login to address 01 - Engine, you should see in the top two fields, the current ECU/software part number on the left, and on the right you will see some additional info that ends with the 4 digit software version number.

Here's a screenshot of the last PD glow plug recall TSB, it shows many of the old ECU part numbers and software version numbers, then what they are going to be changed to after the software update (which goes along with changing the glow plugs).

Easiest way to know if you have the most recent 7V Glow plug software at least.

 

[Concat]

Wow, you guys are awesome.

Version 6110 is what my VCDS is telling me. So I don't have the latest 7v plugs. And Im assuming I don't have the steel 5v ones either. Original 7v seems most likely given the software version?

Anyway, it might be a moot point because I pulled the harness to check the resistance and confirm the bad plug... but each one was giving me a reading of around 1 Ohm.

I'm guessing I might just need a new harness then?

 

[Matt-98AHU]

Wow, you guys are awesome.

Version 6110 is what my VCDS is telling me. So I don't have the latest 7v plugs. And Im assuming I don't have the steel 5v ones either. Original 7v seems most likely given the software version?

Anyway, it might be a moot point because I pulled the harness to check the resistance and confirm the bad plug... but each one was giving me a reading of around 1 Ohm.

I'm guessing I might just need a new harness then?

Unfortunately, the TSB doesn't specifically say which ones are 5V and which are the original 7V software. But it does at least let you know if you have the latest 7V software revision.

I personally would strongly consider getting the update done.

 

[wonneber]

Wow, you guys are awesome.

Version 6110 is what my VCDS is telling me. So I don't have the latest 7v plugs. And Im assuming I don't have the steel 5v ones either. Original 7v seems most likely given the software version?

Anyway, it might be a moot point because I pulled the harness to check the resistance and confirm the bad plug... but each one was giving me a reading of around 1 Ohm.

I'm guessing I might just need a new harness then?

That's what it sounds like.
If you want to verify them I would use a normal power test light.
Clip the lead to the battery positive post and point to the glow plug one at a time.
It should light up equally for each.

 

[P2B]

That's what it sounds like.
If you want to verify them I would use a normal power test light.
Clip the lead to the battery positive post and point to the glow plug one at a time.
It should light up equally for each.

The OP already tested resistance and found them to be equal at 1 ohm. What is the point of testing again using a light?

 

[wonneber]

The OP already tested resistance and found them to be equal at 1 ohm. What is the point of testing again using a light?

I'm not a fan of testing for resistance of high current devices.
I've found even my Fluke will show no resistance with ground wires where a test light (not led) will not be as bright.
Saw this with me 2003 JSW.
Replaced the four glow plugs with Bosh plugs and each had the same brightness.