http://www.vwt4forum.co.uk/showthread.php?t=4530

Hi All I,d thought I'd give something to the Forum for a change. Here's how I changed my Glow plugs on my 1993 2.4D Caravelle. The location of Plug 1 is the left hand side of the engine (Drivers side) First I removed the 4 10mm bolts securing the radiator

Then I pulled the radiator up and out to enable more space in the engine bay to access plugs 4 and 5

Then after removing the Belly pan = 6 13mm bolts & 2 10mm nuts I could see the first 3 plus from below the engine. These are easy to remove with the 8&12mm glow plug spanner from halfords (see later photo) and normal 8 & 12mm spanners

Plugs 4 & 5 are more awkward Plug 4 was only got at by removing the leak off pipes that link injectors 3,4 & 5. I also removed the metal fuel pipes from injectors 4 & 5 - 17 & 13mm spanners. This made plug 4 fairly easy to remove and replace

Plug 5 is the real pain - the only way to get at it is to remove injector No.5 I used a 27mm box spanner - with a long extension bar (it was tight !!) be very carefull not to damage the injector on removal,storage and replacement - same goes for storing the fuel pipes and cover all exposed fuel connectors. Plug 5 can now be seen (just) I removed the plug with the lead still attached with a 12mm ring spanner - it took a long time and a lot of patience. the photo below shows injector 4 and new plug 4 on the left and injector 5 and plug 5 on the right removed

To replace plug 5 I made a holder out of some curtain track and I used this to manouvre the new plug into its hole. I then managed to get my finger onto the bottom of the plug and used a 12mm spanner to slowly tighten the plug into place. access for this plug is very tight due to a casting passing right in front of the hole for the plug. if you thing puttting the plug on if fiddly now try fitting the wire and 8mm nut !! I put some blutack onto my finger and placed the nut on this. I then offered the nut up to the plug and very carefuly tried to tighten the nut with a 8mm spanner. it took a lot of attempts and multiple searches for the dropped nut but it eventually went on Photos show curtain track manipulator !!

This photo shows the special tools not found in a socket set. Please note the 27mm socket that halfords sells is no good for removing injector. I used the box spanner shown in the photo below

After plug 5 was replaced and tightened up with wire fitted I worked in reverse fitting the wire and bar on plug 4 then 3,2 and finally the wires on plug 1. I replaced injector 5 and renewed the leak off pipes on the injectors as they'd had it. I then replaced the copper pipes on injectors 4 and 5. I placed all the nuts bolts and bits in a tin as i removed stuff so I checked this was empty before I tried to start the engine. And Bingo I,ve got a van that starts again !!! Now strip off all your clothes and run down the street cheering (optional) I also replaced the starter motor and fuel filter during this procedure as I,d burnt the starter motor out trying to start the engine with knackered glow plugs, the fuel filter was just old. Beofre I replaced the belly pan I took it for a test drive to check there were no fuel leaks etc.. Well I hope this encourages someone else to have a go as I,m no mechanic, and its fairly easy to do, just fiddly Enjoy T4dave