VW Glow Plugs: Troubleshooting & Replacement

Hello!

Today, a colleague and friend of mine placed four fuel injectors on my workbench.
I need to print something out, and I have a device that can do that.
Background:

The injectors are from an old, non-TDI 1.6-liter VW engine.

Apparently, two of the glow plugs at the top of the engine have burned out.
He mentioned that he once heard it might be related to the nozzles.
I was told something similar at some point.

I have to say, I've often seen injectors that produced a chaotic spray pattern, but the engines didn't have any problems.
I've never seen a burned-out light bulb myself.

I'm going to clean the nozzles this morning.
Can someone tell me something helpful about this?

So is it with my (carefully selected) knowledge.

I only experienced GSK (German term for a specific type of skin condition) on my JP (1.6 naturally aspirated diesel engine with 54 hp in the G2 model), which manifested as "sores" that were kind of puffy and inflamed.

I've only seen descriptions of severely emaciated animals in literature.

m;

Hello,
I also had those burnt and seized glow plugs back when I had my Golf 2 TD.
Since I wasn't very knowledgeable about engines at that time, we always just replaced them. I never tried to figure out the reason why they were burning out.

However, we had to replace the fuel injectors several times because the spray pattern was no longer optimal after 250,000 km, and the cylinder head gasket didn't always appreciate this.

Okay, I can definitely imagine that if the spray pattern is poor, or if the diesel jet (!) directly hits the glow plug, it could cause the glow plug to burn out.

Best regards, Jochen.

Hello!

I checked the nozzles today.
Two of them were okay, more or less.
The nozzle emitted a beam at an angle.
And the last one is completely crazy:
Instead of 180 bar like the others, this one only starts spraying at 250 bar.
and with two sharp, lateral rays.

That was also one of the problem cylinders.

I'm going to install some new injector nozzles now.
I have two sentences that I've been holding onto for years, but I can't remember where I got them from.
These might be suitable for that type of vehicle.

Can someone help me with this?
The injector nozzles are from Monark Diesel, and they have Monark part numbers on them.
When I provide vehicle data or original VW part numbers,
Can someone help me determine if these are the correct words to use, or if "also" should be used instead?
I'd like to install the nozzle inserts before I eventually throw them away.

Hi Steffen!

Hi Steffen,

Is there anything written on the nozzles, like "DN<Something>SD<Something>"? This allows for a clear identification of the nozzle, as most manufacturers have adopted these designations, originally from Bosch, or at least write them on the side of the nozzle. You'll likely find information about the nozzles on Henzo's website (www.dieselsend.de). If not, please post the part number, and I'll check where they originally belong.

If the nozzle sprays at an angle to the side, it can very effectively cut the glow plug, especially if the glow plug is warm or if it's actually too long (A mischievous person might think something different... ), but I've experienced it myself. 180 bar, however, already suggests the use of diesel fuel; originally, turbo models have 155 bar, and naturally aspirated models have even less. If diesel fuel is being used, the glow plugs should also be longer than the standard ones; I use the 23mm glow plugs from Zermedes, which are designed for angled injection. It's also possible that the glow plug system has been modified; a longer afterglow can also promote the complete combustion of such a glow plug.

Smoky greetings.
Peter.

Hello!

The old nozzle inserts all have the number DN O SD 293.
One of them is, oddly enough, 0.25 mm longer than the others... so the solid metal body, that's strange.

I heard about Monark:
39 305 138 243
and
39,305,063 250

Kann mir jemand helfen? Does anything fit?
I just measured them again, and everything is the same.
Only the tip of the needle is slightly different on the older VW injectors. The cylindrical part between the two cones is a bit longer than on the Monark injectors.
However, I can't see any difference between the various Monarch nozzles.

Or am I exaggerating a bit?
Just install any ones you find, and if the engine runs normally, then it's okay?
It's just an old clunker anyway.

Hello Peter vdl!

When I started writing my post (posted at 22:26), your reply (posted at 22:12) had not yet appeared.
I wrote down the numbers at that time.

Regarding the injection pressure:
The printing machine is very old and comes from a workshop of the former German postal service.
and there's a red line painted on the pressure gauge at the 180 mark.
The nozzles also sprayed during that line.
Just not that one particular, very noticeable one (where the nozzle body is slightly longer).

It's quite possible that the pressure gauge is not displaying accurate readings.
Perhaps I can buy a new pressure gauge sometime.
"This part is from Bosch; shouldn't it be possible to get replacement parts for it?"

Hi Steffen,

The DN0SD293 is the original injector nozzle for a whole range of 1.6 diesel engines and their related models from the AuWeh range. It's an injector without a pre-injection function, which is a clear disadvantage when using alternative fuels like rapeseed oil.

I can't directly identify the Monark nozzles without a Monark catalog, but: my ESI system recognizes "Monark 39 305 063," which is a replica of the Bosch "0 434 250 063," also known as "DN0SD193." If the similarity between the last three digits of those numbers is significant... Unfortunately, "0 434 243 138" doesn't seem to be a valid Bosch part number, but "0 434 250 138" is the nozzle type "DN0SD273," which might be a possible match. It's quite vague, but you never know...

The DN0SD193 can be found, among other places, in Fiat, Iveco, and Opel engines, specifically in the Fiat engines 8144.61 and 8144.67, used in some Ducato models; in the Iveco engine 8140.61.2, used in some Daily models; and in the Opel 16 D, DA OHC engine from the Kadett 1.6 D.

The DN0SD273 is a VW injector, with the AuWeh part number 068 130 211 D. It is originally installed in the injector holders of the JK, JP, JR, ME, MF, and MN engines, and also in the Nissan Santana with the CY engine (which is not a VW engine?). It is also a direct injection nozzle without pre-injection.

I would investigate whether the suspicion that the Moark nozzle 39 305 138 243 is actually identical to the Bosch 0 434 250 138 can be confirmed, and if so, I would install these nozzles in the holders. The engine would hardly notice that different nozzles were installed. I would be a bit more cautious with the DN0SD193. If you have to buy nozzles, I would recommend upgrading to the pre-injection nozzle DN0SD297. This improves, among other things, the starting behavior and the exhaust emissions. However, there is no emissions test report for this nozzle in that engine, and therefore, strictly speaking, no approval (ABE) is available.

Smoky greetings.
Peter.

Hi,

die 273er Düsen würden es ohne probleme tun, für Pöl sind 297er jedoch die 1. Wahl.

The CY is a 1.6 TD engine with 51 kW from VW/Audi, and a Santana is a VW Passat 32B station wagon .

Best regards, Michael.

mdonau wrote:

The CY is a 1.6 TD engine with 51 kW from VW/Audi, and a Santana is a VW Passat 32B station wagon

.

Hi Michael,

"I'm familiar with both cars and engines, but my Esi now insists that the car is from Nissan, not from AuWeh. I don't understand the Bosch programmers, especially since Esi claims that the CY in the AuWeh DN0SD293 should be..."

Smoky greetings.
Peter.

Hello!

I finished working on the nozzles today, and everything was okay.
The nozzle with the excessively high pressure didn't belong in the engine; one was marked with 155 bar, while the other was marked with 130.

I ordered some shims from VW, and I also adjusted the problem injector to 130 bar.

And one more thing:
My pressure gauge isn't inaccurate, just the bar scale is on the inside, as I've noticed.
I focused on the external appearance before, which was very foolish of me.

The main purpose of this text is, however, to...
I would like to express my sincere gratitude to everyone involved for the helpful information. Great team here!!!