3 weeks ago I set out to complete the 5 minute job of changing the glow plug on cyl 3 in my 2004 Passat B5.5 TDI with a BHW 2.0L PD (pumpe-duse) engine. It turns out codes on cyl 3 actually refer to cyl 2. As you can see from the below picture my job very quickly turned into a time consuming and expensive adventure.
I've read all of the glow plug forum and have found that some people have had luck getting broken glow plug tips out of the combustion chamber without removing the head. I unfortunately have not had as much luck and am wondering if anyone has actually done this on a PD engine? The injector hole is only bout 7-7 1/2mm in diameter and the glow plug hole is even smaller.
I pulled the injector and confirmed with a bore scope that won't fit all the way into the cylinder that the piece is indeed sitting on the piston head. I spend many hours yesterday with drinking straw duct taped to a vacuum trying to remove the broken tip to no avail.
The dealer wants $1200 to $1800 to remove the head and get the piece out.
I actually don't trust the dealer (although I think the lead mechanic may knows his stuff) and the local technician forum doesn't show any reputable techs in or around Peoria, IL where I live. I'm searching for any ideas or known reputable shops before I ship this thing to the dealership on a flatbed. I was thinking about buying the following bore scope. It will fit in the injector hole but I still don't know how to get the piece out even if I can get it down the hole.
I just wish VW had published a letter about this issue. I would have paid to replaced these with the steel tip plugs had I known about the problem. I guess it comes down to warranty money for VW, as in they don't have to pay if they don't admit there is a problem, but it sure sucks for the customers who have this problem. At least I haven't run the engine since this happened.
Thanks for the help!
I've read all of the glow plug forum and have found that some people have had luck getting broken glow plug tips out of the combustion chamber without removing the head. I unfortunately have not had as much luck and am wondering if anyone has actually done this on a PD engine? The injector hole is only bout 7-7 1/2mm in diameter and the glow plug hole is even smaller.
I pulled the injector and confirmed with a bore scope that won't fit all the way into the cylinder that the piece is indeed sitting on the piston head. I spend many hours yesterday with drinking straw duct taped to a vacuum trying to remove the broken tip to no avail.
The dealer wants $1200 to $1800 to remove the head and get the piece out.
I actually don't trust the dealer (although I think the lead mechanic may knows his stuff) and the local technician forum doesn't show any reputable techs in or around Peoria, IL where I live. I'm searching for any ideas or known reputable shops before I ship this thing to the dealership on a flatbed. I was thinking about buying the following bore scope. It will fit in the injector hole but I still don't know how to get the piece out even if I can get it down the hole.
I just wish VW had published a letter about this issue. I would have paid to replaced these with the steel tip plugs had I known about the problem. I guess it comes down to warranty money for VW, as in they don't have to pay if they don't admit there is a problem, but it sure sucks for the customers who have this problem. At least I haven't run the engine since this happened.
Thanks for the help!
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