Glow Plug Connector Rail Broken

barryg · Mar 10, 2009

I got the engine mgt light on,
I pluged it in got electrical fault to glow plug 2 3 and 4,

When I looked at the plugs they are fine the problem seems to be with the plastic rail that connects to all the plugs, it is cracked on each of the legs that branch off to each plug. one leg is almost fully broken off.
I priced this part with seat they want 570euro +vat for it. It is just a plastic connector!!!!!
they say it is part of the loom ?? There is no connector on this rail to connect it to the loom it seems to be wired directly to somewhere? I didnt trace the wires from it. What I am thinking of doing is cutting the wires that go into my broken rail and spliicing in a new rail (from a scrap tdi) would this work? ?

glynnd · Mar 10, 2009

Yes it would work with no issues, I did it that way on my car!
Part costs around £20 gbp
570 euros? They are obviously looking at the wrong part.
Buy it from uk and get it posted.
Be aware that there are 2 types if your car is 04 or newer then it will probably be the 4 wire bridge. make sure you check before ordering it
Glynn

barryg · Mar 10, 2009

glynnd said:
Yes it would work with no issues, I did it that way on my car!
Part costs around £20 gbp
570 euros? They are obviously looking at the wrong part.
Buy it from uk and get it posted.
Be aware that there are 2 types if your car is 04 or newer then it will probably be the 4 wire bridge. make sure you check before ordering it
Glynn

Ya I went down to the dealer and pointed out the part I needed, it is €30 +vat (that's more like it) not 580!???!
I have the part ordered.
The dealer computer didn't show 2 types, I gave him my engine code so hope it's the correct type. The one on my car had the 4 wires. We will see when it arrives it will tale 3 days.
Thanks a million for the info

wardy2602 · Mar 11, 2009

The part number is stamped into the back of the bridge ( plastic connector )
Its dead easy to fit the end even has a multi plug all you need to do is strip back the harness.

oldman · Mar 12, 2009

glad it is "dead easy to fix" as i'll be doingthis at weekend.

Any guide on where the plug end is located as you say about strip back harness?

i'm a complete noob and plonker under teh hood so good guidance is appreciated as i can't afford garage repair prices at the moment

glynnd · Mar 12, 2009

Its located in the black ducting which drops from the bulkhead area down behind the airbox
Glynn

oldman · Mar 12, 2009

so its a full battery and airbox removal jobbie then?
to access ducting, tape or plasctic surrond thingy, that i guess needs cutting, unplug replug and retape to seal and bob's your uncle.

assume easy enough to remove engine cover and pull the bridge of each plug and then follow cable till the end?

or have i missed something?
i really am a noob you know

Seat Adam · Mar 12, 2009

No thats basically it. It's a little time consuming though. Took me about 2 hrs and an achey back afterwards. Make sure you have your radio code before you start to as you'll need that once you've disconnected the battery. That's if you have the standard stereo fitted.
The plastic bit on the bulkhead has a few clips holing it together, just peel off the rubber strip and remove it. Easy!

glynnd · Mar 12, 2009

Yes the battery does need to come out as the loom runs underneath it.
You can either trace the wires all the way back to the multi plug or you can chop the old bridge out and splice the new one in. I did the latter and have not had any issues in over 6months now. Use 15 amp connectors if splicing in.
Glynn

oldman · Mar 13, 2009

cheers guys, seems simple enough!!
well i could take apart and leave it and tow to garage if make a hash or get lost, which is likely.

yep, got radio code all ok, and will be nice ecu reset while being done.

anybody have aprt number for one, it's an ARL enginer code.
looking on etka v7 update260 i can't seem to locate the right one, and my local vw dealer is also having difficulties.

Seat Adam · Mar 13, 2009

The part number is moulded into the plastic of the bridge. If it's the same as mine which i'm sure it will be, the number is same as VW part number, 038971220D, description is 'Bridge'. Mine cost me £22.59 +VAT in January from Seat dealer.

Fl@pper · Mar 13, 2009

is it #10 or similar depending on engine code year etc

about £30 odd from memory

oldman · Mar 13, 2009

fantastic guys,
Seat Adam; just found that part on etka myself, still learning how to use it fully.
Fl@pper; yep is number 10, or 4 if you look at illustratoion 971-09

also found this very good guide which i will try to follow...
http://forums.tdiclub.com/showthread.php?p=820587

oldman · Mar 17, 2009

afternoon,
just thought i'd an update.

Have removed old and lined up new with a dab of dielectric grease.
very very fiddly though well chuffed all done.

washed all plastic etc, might as well try to make look clean as was filthy, and then put together and hope all ok.

Seat Adam · Mar 17, 2009

Glad it all went ok. You'll probably notice it start a bit better now on colder mornings.

oldman · Mar 18, 2009

that's the thing. it always started fine on freezing mornings.
just had the error at xmas aso changed plugs - no change in startup behaviour
so changed bridge as same fault in vag-com - started her up and again no change in behaviour at all

just hope nothing else is causing the faults...

Seat Adam · Mar 18, 2009

Well if it does now all you've got left to change is the glow plug relay. You've eliminated everything else.

glynnd · Mar 18, 2009

When the bridge starts to fail it will work intermittently. So sometimes you will get normal performance from the glow plugs. If you have replaced the bridge and erased the fault then you will know all is ok when the light stays out. The check light will come on after a number of starts where the bridge does not give a full connection to the plug(s), this could take a couple of weeks even. So you may not alwys notice a poor start performance if only one of the plugs does not get a full connection from the rail.
Glynn

oldman · Mar 18, 2009

cheers guys.
yep cleared fault this afternoon after looking in vag-com section on how to do that.
will know next week i suppose as on hols this so not being used much, if at all.
exams need doing

cuprakitty · Mar 20, 2009

I have the recurrent engine management light (getting irritating now), the familiar fault codes reported for glowplug circuits 2 and 3... and the wiring harness/bridge on order from the local SEAT dealer! My preferred VAG specialist will fit it next Tuesday. This and other threads on the same/similar have been very helpful - thanks, guys

But I've a query on the matter of "poor start performance" - the only noticeable startup issue I have had since the blessed thing's been acting up is a puffy cloud of greyish blue stinky smoke almost every time. On cold days, there's been the odd stutter but no trouble actually starting. Do these symptoms fit the experience of others?

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Glow Plug Connector Rail Broken

barryg

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glynnd

barryg

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wardy2602

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oldman

glynnd

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Seat Adam

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glynnd

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Seat Adam

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Fl@pper

Back older greyer and less oilier but always hope

oldman

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Seat Adam

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cuprakitty

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