Question on Replacing Glowplug Harness in '05 PD (BEW)

[jimnms]

I started getting a CEL for the #2 glowplug a few weeks after my 10k oil change. Since it was still summer, I put off checking it, but now that the weather is getting cooler, I decided to take care of it.
I looked at the Glow Plug 101 Guide for testing the glow plug and harness. I suspected the harness because I could clear the code and would not come back sometimes for several days and sometimes the next day. When I started to pull the harness off the glow plugs, the plastic started disintegrating in my hand. The #1 glow plug popped right off, but then the #2 glow plug just fell apart, and I had barely pulled on it. Part of it remained on the glow plug and the rest came off. I didn't bother with the other two since I now know the problem.
It appears the glow plug harness for the '04-05 engines is different. The guide on replacing the 4-wire harness is for an '02 and it says there is a connector under all that mess. I looked up the harness for the '05 on IDparts and it looks like the replacements has a connector at the harness (which should make future replacing easier), but it has a lot of wire behind it. Does this mean there is no connector on the other end or are you supposed to re-use the old connector. If you're supposed to cut the wires and splice in the new one, it seems odd to give you so much extra wiring.

 

[gatz]

There is no dedicated connector, it is part of a larger harness. They give you all that wiring because the larger harness is located here ^

If you wanted to actually insert it into the connector you would need to buy new pins and a pin removal tool. Nobody goes to that effort, but that's why the wires are so long. Easiest place to splice it is right at the engine, but literally anywhere along the path is fine.

 

[PGM jetta]

^^ Yep, no actual connector on the harness. The idparts picture shows a flexible end on the harness, not a connector. Either crimp or solder the wires together (huge debate wars on which is better, just do whichever you feel the most comfortable doing) the important thing is to weather proof your connections

Oh and idparts is having a November sale on glow plugs and harnesses, so good timing

 

[Mike_04GolfTDI]

My harness was replaced years ago as part of a recall. They just spliced the new harness onto the old wires and left a huge bundle of wire coiled up. It works so I haven't bothered to make it look pretty. (It has been about 10 years)

 

[BobnOH]

3 choices.
1. replace it all the way back to the duct. A bit tedious.
2. Splice it in near the engine. Go ahead and inspect the wires to and in the duct.
3. Rebuild what you have, some creative members have threads on here showing how-to. Thoroughly inspect the wires to remain.

 

[JB05]

Mine fell apart also when changing my #3 GP. I chose Bob's number two choice above. I cut off about seven feet of the new wires and butt connected near the battery. A few weeks later I was able to put one of the cut off wires to good use to run a ground from my driver's door puddle light. This saved me the trouble of tearing apart the door to change the lock assembly.

 

[Metal Man]

On an BEW the relay is under the cowling. I run the wires all the way to the relay and splice there. Stagger the connectors so you have less of a bundle when you're done.

 

[jimnms]

Thanks everyone. I looked at the picture on IDParts again and now see that it isn't a connector like I thought. Has anyone spliced on a 4-wire connector after cutting off the old harness to make future changes easier? Although, since this one lasted me over 10 years, it probably isn't worth the extra time.

 

[JB05]

I was considering using bullet connectors but decided not to. I'm surprised that a harness arrangement up front was not installed at the factory.