← Transporter Volkswagen Transporter repair manuals →
Autopapyrus · Volkswagen Transporter T5 2.5 TDI (AXD) (2003)
https://autopapyrus.com/guides/volkswagen/transporter/glow-plug-removal-and-installation/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Volkswagen Transporter T5 2.5 TDI (AXD) (2003): Glow Plug Removal and Installation

The AXD engine is a five-cylinder, so you need 5 glow plugs. Glow plugs often seize in the cylinder head, and the main risk of this job is snapping a plug off in the head. Work only on a cold engine, soak the threads with penetrating oil beforehand, and loosen the plugs without jerking.

Difficulty: Medium Time: 1.5-3 hours Steps: 14

Parts

2
№Part
01 Diesel glow plugs, 11 V5 pcs, one per cylinder
02 Glow plug wiring harnessif the wiring is in poor condition

Tools

8
  • Socket set and ratchet with extension
  • low-range torque wrench (5-25 N·m)
  • deep glow plug socket
  • multimeter
  • penetrating oil (WD-40 or equivalent)
  • copper anti-seize grease for threads
  • thin screwdriver
  • container for fasteners
There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes and 21 more. See manuals →

Step by step

14 steps
  1. The engine must be completely cold. Disconnect the negative battery terminal. If the vehicle has a radio with a security code, make sure you know the code beforehand.
  2. Remove the upper decorative engine cover and anything that blocks access to the glow plugs: air ducts and hoses, and if necessary the air filter housing or resonator. Cover the intake openings with a clean rag so nothing falls inside.
  3. Locate the glow plugs: each cylinder has a glow plug with a terminal where the power feed connects. Disconnect the glow plug connector or power rail. Remember or photograph the position of the wires.
  4. Check the resistance of each glow plug with a multimeter: a good plug has low resistance, on the order of a few tenths of an ohm up to a few ohms. An open circuit means the plug is faulty. Replace the whole set.
  5. Blow out the wells around the glow plugs with compressed air or clean them with a brush so dirt does not fall into the cylinder when you remove the plugs.
  6. Apply penetrating oil to the base of each glow plug and wait 10-15 minutes. If the threads are tight, warm the engine up to warm (but not hot), shut it off and let it cool to a safe temperature, then repeat.
  7. Unscrew the glow plugs with a deep socket and extension, strictly in line with the axis, without tilting. If a plug turns hard, rotate it a quarter turn back and forth and add more oil. Do not apply great force: the plug breaks easily.
  8. If a plug breaks and part of it stays in the head, do not try to knock it out. Hand the job over to a repair shop: extracting the broken piece requires special tools and removal of the cylinder head or specialized equipment.
  9. Inspect the old glow plugs: carbon buildup or melting at the tip can point to injector problems or overheating.
  10. Lightly coat the threads of the new glow plugs with copper anti-seize grease, keeping it off the working tip. Thread them in by hand until they stop, so you do not cross-thread them.
  11. Tighten with a torque wrench. The approximate glow plug torque for this engine is 15-20 N·m (11-15 lb-ft) (verify the exact value against the manufacturer's specification). Tighten the terminal nuts or screws very lightly, about 2-4 N·m (1.5-3 lb-ft), otherwise you can strip the terminal thread.
  12. Reconnect the glow plug power feed and check that the connector clicks into place and the wires do not touch hot parts or each other. If the insulation shows signs of melting, replace the harness.
  13. Install the hoses, air filter and engine cover, and connect the battery.
  14. Turn the ignition on for a few seconds, wait for the glow plug indicator light to go out, then start the engine. Check for smooth running on a cold start and for any fault codes. If there is a fault code for the glow plug circuit, read and clear it with a scanner.

Common mistakes and warnings

  • The main danger is snapping a glow plug off in the cylinder head, so do not force the removal and do not work on a hot engine
  • Do not let dirt or broken pieces fall into the cylinder
  • If you have no experience with cylinder head threaded connections, it is better to leave the job to a repair shop