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I like fixing things.

I like things not being broken first and foremost, but if they are, I like to set them proper again. I especially like doing simple fixes on the cars.

The 2000 New Beetle TDI we picked up last year had a check engine light on for a bad glowplug – the common P0380 code. When Jason did the timing belt (only 20k miles overdue, stupid-assed previous owners) he swapped it out for a known good used glowplug. Eventually that GP failed again, so I ordered a new set of Beru GPs from TDIParts and Peter was nice enough to bring them with him to a wrenching GTG in Fond du Lac, Wisconsin. Didn’t get them installed that day, as Matt was nice enough to reset the CEL and it didn’t come back.

A few weeks later, the CEL came back.

At that same GTG, I installed a zerostart kilowatt coolant heater in my 2006 Golf TDI but didn’t finish wiring it up.

This past Sunday, 2007 Dec 09, I fixed both issues. I had to venture out to get a 1/4″ drive 10mm deep socket and a can of P’Blaster, but otherwise everything was completely straightforward, as such:

1. Remove engine cover (2x10mm nuts)
2. Remove glowplug harness. Pull hard, it’s on there but good.
3. While engine is still warm, spray the base of the GPs with P’Blaster.
4. Test GP resistance with multimeter. Notice GP in 3rd cylinder measures 24 megaohms while everyone else measures 0.3 ohms.
5. Ponder if GPs are numbered backwards from cylinder order, such that cylinder 3 (3rd from timing belt side) actually has glowplug 2.
6. Remove a GP with the deep 10mm socket.
7. Put a TINY dab of antisieze on the new GP’s threads, gently place it in the hole and hand tighten. Make sure you don’t let any crud fall down in there. Tighten further using your hand on the center of the ratchet or with a torque wrench to 15 Nm (11 ft-lbs). That ain’t much. Be careful.
8. Repeat steps 6 & 7 for the remaining 3 GPs, put the harness back on and start it up to listen for leaks.

Still need to get the CEL reset, but there might be a copy of VAG-COM in my future.

The Golf got the final electrics installed for the Zerostart and it works perfectly. It’s on a 1500W appliance timer to turn on a few hours before I leave for work. Tried it out yesterday for about 1.5 hours before I typically leave and the temp gauge was above the “cold” side at initial start, then dropped down a bit but was back up over them by the time I passed Western Ave. This morning with 3 hours of preheat, it was almost completely warm and only a slight dip in temperature once I got going. Thermosiphon really works well for circulation & having a car that’s already 60% warmed up by the time I start the key is great. Just need to get a reliable parking spot at work near an outlet and I’ll be a happy camper all winter.