All about

Glow Plugs

Start
Diesel Cold
Technology
H N IC AL IN FORMATION
TEC
Contents

The diesel engine 3

Function 3

Cold start 3

Injection system 4

Self-regulating pencil type glow plugs 5

Requirements on a modern glow plug 5

Design and function 6

Post-heating glow plugs (GN) 7/8

The Instant Start System (ISS) 9

System concept 9

Electronic control 9

BorgWarner – Lead innovator for the

use of PSG pressure sensor glow plugs 10

BorgWarner –
Ceramic glow plug (CGP) 10

BorgWarner quality 11

Cheap designs –
something you should do without 12

Causes of failure in glow plugs 13

Workshop tips 14
How to start the diesel engine quickly and safely 14

Torques 15

Special tooling (reamer): for a quick and reliable cleaning

of the cylinder head bore 15

2
The diesel engine

Function
Diesel engines are compression-ignition engines, which means: the injected fuel ignites without the
need for an ignition spark. The combustion cycle is triggered in three steps:

1. First, clean air is taken in.

2. This air is compressed to 30–55 bar – during this process, it will heat up to 700–900 °C.
3. Diesel fuel is injected into the combustion chamber. The high temperature of the
compressed air triggers auto-ignition, internal pressure strongly increases and the
engine does its work.

Compared to spark-ignition engines, compression-ignition engines require complex injection systems

and engine designs. The first diesel engines were not actually very convenient or smooth-running
drive units. Due to the hard combustion process, they made a lot of noise when cold. Typical
characteristics included a lower power-to-weight ratio, a low output per liter displacement as well as
a lower acceleration performance. Through continuous development of the injection technology and
the glow plugs, it was possible to eliminate all these disadvantages. Today, the diesel engine is
considered an equivalent or even better power source.

Cold start
The term “cold start” describes all start processes occurring while the engine and the media
involved have not reached operating temperature. The lower the temperature, the less favorable
are the conditions for a quick ignition and complete, environmentally friendly combustion. Certain
supporting measures are used to assist during the cold start and so that starting will not be
unacceptably long or even impossible. These compensate for the poorer start conditions while
initiating a well-timed and even ignition to ensure stable combustion.

The glow plug is one component that assists during cold start. It creates ideal ignition conditions
for the injected fuel through elec­trically generated thermal energy that is brought into the
combustion chamber. It is indispensable as a cold start aid for engines with a divided combustion
chamber, in order to ensure that these can start even in the frequently occurring temperature
range of 10–30 °C. Since the start quality deteriorates considerably at below freezing point, the
glow plug is also used as cold start aid for direct-injection diesel engines.

3
The diesel engine

Injection systems
Depending on the design and arrangement of the combustion chamber, a distinction
is made between the following three injection systems in diesel engines:

1. Antechamber system
2. Turbulence chamber process
3. Direct injection

Glow plugs are required for all systems – to ensure that the injected fuel can
evaporate and the fuel-air mixture can ignite on the hot surface of the plug.

ANTECHAMBER SYSTEM
In this system, the combustion chamber is divided into two: 1

an antechamber and the main chamber. These are connected with one another by
3
several bores (injection channels). During the compression stroke, a part of the 2

compressed air is forced into the antechamber. Shortly before reaching the top dead 5
centre, the fuel is injected through a nozzle directly into the antechamber of the
respective piston. This is where the injected fuel is partially combusted. The high
temperatures generated ensure a rapid increase in pressure. The entire contents of the
antechamber are thus blown through the injection channels into the main combustion
chamber, where the actual combustion takes place.
1
TURBULENCE CHAMBER PROCESS
The spherical turbulence chamber is arranged in the cylinder head, separately from the 4
2
main combustion chamber. Main combustion chamber and turbulence chamber are
5
connected by a wide-diameter injection channel. During the compression stroke, the
injection channel in the turbulence chamber causes intensive rotation of the intake air.
The diesel fuel is injected into this air turbulence. Combustion starts in the turbulence
chamber and then spreads through into the main combustion chamber.

DIRECT INJECTION
In diesel direct injection (fuel-air introduction), the fuel is injected at high pressure
2
through the multiple-hole nozzle into the highly compressed intake air for atomization;
during this process, the special piston crown design helps with mixture formation. 1

5
During start, the cold intake air is very quickly heated up due to the high compression
pressure. The heating element projects into the main combustion chamber. In principle,
the glow plug in direct injection engines has the same function as in the chamber
engines: it helps with ignition during the start. The heating element of a modern glow 1 Injection nozzle
plug reaches a temperature of over 1,000 °C within only a few seconds. 2 ­
Glow plug
3 ­Antechamber
With cold starts, the situation is generally as follows: the cold air that is drawn in 4 ­
Turbulence chamber
produces lower temperatures at the end of the compression stage. While driving, 5 ­
Combustion chamber
the temperature of the compressed air is adequate for self-ignition. However, it is
not sufficient when starting, especially with low outside temperatures. But it is the
low starting revs that have more serious consequences. Due to the long dwell time
of the charge, the loss of temperature and pressure is much greater than, for
example, when idling.

4
Self-regulating pencil type glow plugs

Requirements on a modern glow plug

SHORT HEAT-UP TIME
Glow plugs must provide a high temperature within as short a time as possible to
assist with ignition – and they must maintain this temperature regardless of the
ambient conditions, or even adjust the temperature depending on them.

SMALL SPACE REQUIREMENT

In modern diesel engines with common rail or pump-nozzle injection systems and
4-valve technology, the available space is very restricted. This means that the space
required for the glow plug must be reduced to a minimum, resulting in a very thin
and long shape. Today, BorgWarner glow plugs with glow tube diameters reduced to
<3 mm are already in operation.

PRECISE ADAPTATION TO THE COMBUSTION CHAMBER

Ideally, the glow rod should be situated precisely at the edge of the mixture vortex –
however, it must still project sufficiently deep into the combustion chamber or the
antechamber. Only then is it able to introduce the heat accurately. It may not
protrude too far into the combustion chamber, as it would otherwise interfere with
the preparation of the injected fuel and thus the preparation of the mixture for an
ignitable fuel-air mixture. This would result in increased exhaust
gas emissions.

SUFFICIENT GLOWING VOLUME

Apart from the glow plug, the injection system is of particular significance in the
engine cold start. Only a system that has been optimized in terms of its injection
point, quantity and mixture composition in conjunction with the correct position and
thermal rating of the glow plug will ensure good cold start performance. Even after
the engine has been started, the glow plug may not be “blown cold” by the increased
air movement in the combustion chamber. Very high air speeds are in particular
present in antechamber or turbulence chamber engines at the glow plug tip. In this
environment, the plug will only work if it has sufficient reserves; i.e. if sufficient
glowing volume is available so that heat can immediately be brought on into the
cold-blown zone.

The glow plugs developed by BorgWarner fulfill all these requirements in an optimal
manner. BorgWarner engineers work closely with the automotive industry especially
during the engine development stage. The result: an environmentally-­sound diesel
quick start in 2-5 seconds (in conjunction with the Instant Start System ISS a
maximum of 2 seconds), a reliable start up to –30 °C, a steady engine start-up that is
gentle on the engine, with up to 40% less carbon-particulate emissions in the warm-up
phase for post-heating glow plugs (for more information see from page 7 onwards).

However, even after a cold start and warm-up phase, glow plugs are still active in
modern diesel engines. With the so-called intermediate glow, the innovative glow
plugs from BorgWarner ensure that the exhaust gas temperatures do not drop too far,
even in stop/start and overrun operation. This ensures low-noise and low-emission
combustion in every engine operating condition. At the same time, soot deposits in
the diesel particulate filter and the exhaust gas recirculation valve are reduced. The
ISS glow plugs from BorgWarner, for example, offer long glow times of 5-8 minutes in
conjunction with high temperature resistance and long service life.

5
Self-regulating pencil type glow plugs

Design and function

The BorgWarner glow plug basically comprises the plug body, heating rod with
heating and regulating coil, as well as the connecting bolt. The corrosion resistant
glow rod is pressed in the housing so that as to be gas-tight. The plug is
additionally sealed by a sealing ring or a plastic component at the connector.
A battery supplies the electrical energy for the glow plug. It is controlled by an
electronic glow time control unit.

HEATING AND REGULATING COIL

The basic principle of a modern glow plug is the combination of a heating and Connecting
a regulating coil into a single common resistor element. The heating coil is made bolt
of high-temperature resistant material the electrical resistance of which is largely
Round nut
temperature-independent. Together with the front part of the glow rod, it forms
the heating zone. The regulating coil is attached to the live connecting bolt; its Insulation disc
resistance has a large temperature coefficient. O-ring seal

Plug body
The entire coil is firmly packed in a compressed, electrically insulating but highly
heat-conductive ceramic powder. During mechanical compaction, the powder is
compressed so much that the coil is fitted as if it was cast in cement. This makes it Gasket
so stable that the thin wires of the heating and regulating coil can permanently
resist all vibrations. Even though the individual windings are arranged only a few
tenths of a millimeter apart, no winding short circuits can be produced – and
certainly no short circuit to the glow tube, which would destroy the plug.
Insertion
thread
With the different materials, lengths and diameters, and different wire thicknesses
for the heating and regulating coil, it is possible to change the heat-up times and
glow temperatures of the plug in accordance with the respective requirements of
the engine.
Annular gap

FUNCTION
During pre-heating, a high current initially flows via the connecting bolt and the Glow tube
regulating coil to the heating coil. The latter heats up quickly, causing the heating
zone to glow. Glowing quickly expands – after 2–5 seconds, the heating rod glows
Regulating coil
up to near the plug body. This additionally increases the temperature of the
regulating coil that has already been heated up by the current. Then, the electrical Insulating
filling
resistance increases and the current is reduced to a point where it cannot cause
Heating coil
any damage to the glow rod. Overheating of the glow plug is thus not possible.

If the engine is not started, the glow plug will be switched off by the glow time
control unit after a certain stand-by time.
Design of a self-regulating,
fast-heating pencil type glow plug.
The resistance of the alloy used on BorgWarner glow plugs increases with the
tempe­rature. It is thus possible to design the regulating coil in such manner that
it will initially let through a higher current to the heating coil than when it reaches
the target temperature. The target temperature is thus reached quicker and is
main­tained within the permissible range by an increased regulating effect.

6
Self-regulating pencil type glow plugs

Post-heating pencil type glow plugs (GN)

Older vehicle models are normally equipped with glow plugs that
The 3-phase glow technology.
only glow before and during the start phase. They can be recognized
from the abbreviation GV. Modern Diesel passenger cars normally T (° C)
leave the assembly line with fitted GN glow plugs. They are 1.000
equipped with the innovative 3-phase glow system. This means that 850
they glow

– before the start,

–  uring the start phase,
d
– after the start, and
– during engine operation (in coasting mode).
Phase 1 Phase 2 Phase 3

FUNCTION Pre- Start Post-heating

heating heating approx. 180 sec.
The electronically controlled pre-heating starts when the ignition 2-7 sec. 2 sec.
lock starter switch is operated and lasts for approx. 2-5 seconds at
normal outside temperatures until the engine is ready to start. The
post-heating time is up to 3 minutes after starting the engine to Three-phase
reduce pollutant and noise emissions to a minimum. alternator

Battery
The engine operating state is registered e.g. by measurement of the Ignition lock
coolant temperature. The post-heating process is continued until the starter switch

Starter
coolant has reached a temperature of 70 °C, or it will be switched off
after a certain time which is set in the performance map. No post- Electronic
heating will normally take place if the coolant tem­perature was Indicator control unit
lamp
already higher than that before starting.

PROTECTION AGAINST OVERHEATING

Self-regulating glow plugs restrict the current flowing from the
battery to the plug with increasing temperature to prevent Circuit design principle for a post-heating
glow system with four fast-heating glow plugs
overheating. However, when the engine is running, the voltage will connected in parallel and a temperature sensor.
increase to a point where glow plugs that do not comply with the
newest technology will blow. Besides, the plugs that are supplied
with current are exposed to high combustion temperatures after the
start, and are thus heated up from the inside and the outside. The
post-heating BorgWarner glow plugs are functional at full generator
voltage. Their temperature increases very quickly, but will then be
limited by the new regulating coil to a saturation temperature that is
lower than that of non post-heating plugs.

IMPORTANT
Only GN glow plugs may be installed in a glow
system designed for GN glow plugs – GV glow plugs
could be damaged very quickly.

7
Self-regulating pencil type glow plugs

QUICK START IN 2 SECONDS

With the post-heating BorgWarner GN glow plug, it is possible to reduce the glow
time to 2–5 seconds. To achieve this, the designers reduced the diameter at the front
end of the heating rod. The heating rod thus starts glowing quicker in this zone. At a
temperature of 0 °C, this takes just 2 seconds until start. When temperatures are
lower, the system is accordingly adapted to the requirements by the glow-time
control, and glow time will respectively increase: at –5 °C approx. 5 and at –10 °C
approx. 7 seconds.

REDUCTION OF WHITE/BLUE SMOKE

So-called white or blue smoke is emitted from the exhaust until the ideal ignition
temperature has been reached. These types of smoke produced are the result of
incomplete combustion of the fuel, resulting from too low an ignition temperature.
Post-heating causes the diesel fuel to burn more completely and with less noise
during the warm-up phase. Smoke opacity is thus reduced by up to 40%.

ELIMINATION OF COLD-START KNOCKING

Knocking during cold-start of a diesel engine is caused by an increased ignition
delay when the engine is cold. The fuel ignites abruptly, and the engine knocks.
Pre-heating and post-heating of GN glow plugs ensure that the engine reaches the
operating temperature quicker. This preserves the engine, results in quieter engine
running and prevents knocking. The fuel will then be burnt more evenly and more Carbon deposits in the
filter paper three minutes
completely. More energy is thus released and the combustion chamber tempera­ture after the cold start. With post-
will increase faster. heating (on the right), carbon
deposits are approx. 40% less
than without post-heating.

Technical features
of the GN glow plug
– Quick-start glow plug in slim design
– Short pre-heating time:
only approx. 2–7 seconds
– Reliable start (even at –30 °C)
– Environmentally friendly:
approx. 40% less pollutant emission
during the warm-up phase
– No knocking
– Quieter engine running
– Start is gentle on the engine
– For vehicles with operating
voltages up to 14.5 V

8
The BorgWarner Instant Start System (ISS)
To make a key-turn start possible for diesel fuelled vehicles resembling
that for a spark ignition engine – that was the great challenge.
The solution from the BorgWarner engineers: the Instant Start System ISS.

System concept
The BorgWarner ISS comprises an electronic glow plug control unit and perfor­
mance-­optimized glow plugs with a reduced heat-up time of maximum 2 seconds –
compared to approx. 5 seconds (GE-types) for a standard glow plug (SR). Both in the
heating-up and in the saturation phase, they require significantly less energy.

Power semi-conductors are used in the control unit as switches to control the glow
plugs, replacing the electro-­mechanical relay used in the past. Compared to the
conventional self-regulating glow plugs, the winding combination of the power-­ Interior structure of the self-
regulating standard glow plug
optimized glow plug of the ISS is considerably shorter and the glowing area is SR (left) and the power-
reduced to approximately one third. In direct-injection engines, this corresponds to optimized ISS glow plug
the part of the heating rod that protrudes into the combustion chamber. (right).

Electronic control
When the engine is running, the glow plug is cooled by the change in the charge
and air movement in the compression phase. The temperature of the glow plug
will decrease with increased speed for a constant glow plug voltage and injection
quantity, and will increase for an increasing injection quantity and constant glow
plug voltage and speed. The electronic control unit can compensate for these
effects: the glow plugs are always supplied with the optimal effective voltage for Electronically controlled
glow system ISS: Control
the respective operation point. The glow plug temperature can thus be adjusted unit and glow plugs.
depending on the operating state. In addition, the combination of the low-voltage
glow plug and the electronic control unit is used for heating up the glow plug
extremely quickly. This is done by feeding the full on-board voltage to the glow
plug for a pre-defined period, and only then operating with the necessary
effective voltage during synchronized operation. The normal pre-heating period
is thus reduced to a maximum of 2 seconds even at low temperatures. The
efficiency of the system is so high that not much more than the power required by
the glow plug is taken from the on-board power supply. As each glow plug can be
controlled by a separate power semiconductor in the ISS, the current can be
monitored separately in each glow current circuit. Individual diagnostics at each
plug is thus possible. The BorgWarner Instant Start
System enables key-turn
start for compression-ignition
When using the BorgWarner Closed Loop Control Module, the voltage is set by the engines just like that for a
microcontroller with a programmed controller so that the heating is always efficient spark ignition engine.

and the requested temperature is maintained.

Technical features of the ISS

– Reliable start even at temperatures of –30 °C – Numerous diagnostics functions
– Extremely fast heat-up time: 1,000 °C are reached – Controllable temperature for pre-, intermediate
in max. 3 seconds (GE-types) 850 °C are reached and post-heating
in 2 seconds (SR) – Immediate stable idling and well-controlled load take-up
– Low power requirement (in particular important for – Minimised pollutant emissions
engines with 6 or more cylinders) – Specifically designed for diesel engines with direct injection
– Higher functional reliability – On-board diagnostics-enabled

9
BorgWarner – Lead innovator for the
use of PSG pressure sensor glow plugs
INTELLIGENT PRESSURE-SENSOR GLOW PLUG
New emission laws in Europe and in the US will further reduce the permissible
exhaust gas emissions of diesel engines. The thresholds for NOx and particulate
emissions, which are relevant for the diesel engine, will in future significally lower
than before. It will not be possible to comply with these emission standards with
conventional solutions alone.

BorgWarner developers have integrated a piezoresistive pressure sensor into the

plug. In view of the extremely high temperatures, vibrations and pressure conditi-
ons in the cylinder head, the mechanical design of the glow plug is an important
Connector High-current connection
success factor. The heating rod is not pressed in the glow plug body, as was the
standard in the past, but is supported elastically as mobile component, and it trans­mits Measuring
diaphragm
the pressure to a diaphragm located in the rear area of the glow plug. The actual
pressure sensor is thus positioned far away from the combustion chamber in an Glow plug
heating rod
area with significantly more favorable ambient conditions. Thermal load on the
seal remains controllable due to the use of a heating rod from the BorgWarner PC board with
electronics
Diesel ISS quick-start system, which only glows at its tip.
Glow plug body Gasket
The intelligent PSG (pressure sensor glow plug) is used in diesel engines made
by Volkswagen, Audi, BMW/ Mini, Opel and Renault.
The intelligent PSG
(pressure sensor glow plug).

BorgWarner –
Ceramic glow plug (CGP)
STRONG INNER VALUES
New emission laws in Europe and in the US will further reduce the permissible The
composition of the materials is crucial to the performance of BorgWarner ceramic
glow plugs. High strength silicon nitride ceramic to enclose the electrically conductive
Molybdenum disilicide inside an interpenetrating structure. This material withstands
pressures up to 200 bar and temperatures up to 1,300°C – all in the various gaseous
atmospheres encountered in the combustion chamber (ambient air, diesel, oxygen
and water).

PERFORMANCE DRIVEN TO THE TIP

Besides short heat-up times, the externally positioned heating rod design, of course
The microstructure of the
patented, also provides optimized regulation. Moreover the plug’s heating capacity BorgWarner glow plug
concentrated at the tip of the ceramic element requires less energy to generate the ceramic with strengthening
small silicon nitride rods and
temperature required to start the engine – and thus uses less fuel compared with white Molybdenum disilicide
conventional plugs. Besides increasing the operating reliability, the resistance within grains, which form the
electrically conductive,
the regulation system, ensures the BorgWarner ceramic glow plug has the best three-dimensional structure.
possible energy balance at every engine operating point. This also contributes to a
reduction in consumption and emissions.

10
AN EXCLUSIVE PROCESS The structure of the ceramic heating
rod on the BorgWarner glow plug
BorgWarner ceramic glow plugs are manufactured on
patented series production facilities. The ceramic heating
Glow plug contact
element is produced in an extrusion and injection molding Insulator
process. This is followed by processes to relieve, sinter and
harden them to produce the tight tolerances required before Internal
they can be fitted into the metal bodies. This requires several conductor
External
grinding procedures, and due to the extreme hardness and Heating
conductor
Cap area
strength of the materials, the grinding must be performed section Cap

with diamond tools. The ceramic heating rod contact is

produced in special high-temperature procedures over the full
surface. This achieves high resistance capacity against
The heating element consists of electrically
oscillations and temperature changes. With the combination conductive solid ceramic. Because this has a
of high-strength material, innovative construction and the higher specific resistance at the surface than the
supply and return conductor material, the glow
latest production processes, BorgWarner ceramic glow plugs rod only glows at the tip (the cap) thus reaching
offer outstanding features. high tempe­ratures faster than other ceramic blow
plug technologies (BorgWarner patent). The
glow plug contact consists of an internal and
external conductor with an insulator positioned
between them.

BorgWarner glow plugs:

Fivefold safety for maximum quality
1. DESIGNED IN CLOSE COOPERATION WITH CAR MANUFACTURERS
As diesel cold-start specialist and development partner of the automotive industry, BorgWarner has not only been
involved in the glow plug design from the beginning, but was already present and involved during the development
of new engines. It was therefore possible precisely to coordinate the installation position of
the glow plug within the engine – and BorgWarner engineers know exactly what parameters are particularly
important or what performance reserves must be possessed by the glow plug under development.

2. MANUFACTURED ACCORDING TO ISO STANDARDS

BorgWarner glow plugs are designed in compliance with ISO Standards. These specify the dimensions and
tolerances of the geometry, the sealing angle, the wrench size, the heating rod diameter, etc.

3. DEVELOPED ACCORDING TO THE PRODUCT SPECIFICATIONS OF THE AUTOMOTIVE INDUSTRY

BorgWarner glow plugs fulfil the product specifications of automotive industry, which vary from one vehicle
manufacturer to the next. Thus, for instance, between 10,000 and 25,000 cycles are required for continuous operation.

Furthermore, BorgWarner glow plugs must survive test runs in the cold chamber. In addition, tests are made on
resistance to environmental influences, contact media, additives and engine cleaners.

4. SUBJECTED TO SPECIAL BorgWarner TESTS

BorgWarner glow plugs undergo special test runs that have been adapted to the practical requirements for
everyday operation and for the workshop, for instance through simulation of connector pull-off forces or quick
overload tests. The test personnel are unrelenting in these quick overload tests: Every test specimen must still be
fully functional even after 3,000 cycles.

5. MANUFACTURED ACCORDING TO THE LATEST PRODUCTION METHODS

The manufacture of the extremely long and slim modern glow plugs for direct injection diesel engines brings
particular challenges. The diameter of the glow tube must be exactly adapted to the combustion chamber. A precisely
dimensioned length of the glow tube must project into the combustion chamber – only then can it be ensured that the
turbulence will not generate any additional harmful emissions. The temperature properties of the glow plug must also
be accurately suited to the combustion chamber design – and the current consumption of the glow plugs must be
precisely adapted to the existing on-board power supply. Only the latest production facilities, such as those operating
at BorgWarner, provide the conditions for manufacturing these slim glow plugs to the desired quality.

11
Cheap designs – something you
should do without
2-COIL OPTICS, BUT ONLY 1-COIL TECHNOLOGY
1
Only a 2-coil glow plug achieves the short heat-up time and temperature resistance 16
demanded by car manufacturers. However, as the second coil is not immediately
visible from the outside, some manufacturers spare themselves the so-called
regulating coil. The lack of limitation of the glow current puts excessive stress on the 2
battery during start – and since the required heating is not achieved within the 15
prescribed time, the vehicle will not start, or only with difficultly. (See Figure 3)
3
HEATING ROD FILLING USING LOW-QUALITY INSULATING POWDER
14
Instead of the magnesite powder that is used by BorgWarner, which is compressed
and dried before filling, cheap glow plugs normally employ loose, in some cases
contaminated, insulating powder that is put in without drying. Fatal consequence: 4/5
During first glow process, the powder expands significantly, and the glow tube 13
inflates. The glow plugs can then only be removed by disassembling the cylinder
head! (See Figure 9) 5/6

HEATING COIL NOT CENTERED AND CRIMPED AT THE CONNECTION PIN 12

Production quality shows here as well: only the latest production machines can accu-
rately center and crimp the connection pin. Dubious manufacturers manage by 7
simply push fitting the heating coil onto the connection pin. However, the required
11
protection against short-circuiting cannot be guaranteed in this manner.
(For this, please see Figures 5 and 13) 8
17
DEFECTIVE CONTACT
10
In low quality glow plugs, the position of the electrical connection lugs does not
9
comply with the OE specifications. Even though the connection looks similar to that
of the original glow plugs, the contact will not be completed correctly. The electrical
connection to the glow plug is thus not guaranteed. Some of these manufacturers
also save on the material for the connecting components – at the cost of the electri-
cal contact. (See Figure 16)

GLOW TUBE NOT ACCURATELY WELDED

Many cheap manufacturers do not have the production technology to accurately
weld a glow tube. The result: Hairline cracks in the glow tubes – and thus leaks,
which again could result in short-circuits.

HOW TO RECOGNIZE LOW-QUALITY GLOW PLUGS

SYMPTOM RISK SYMPTOM RISK

1 Single sealing Not waterproof 11  low tube tip twisted off,
G Scale deposits, reduced service life
2/9 Filling the glow tube with grade Bad insulation, swelling of the heating rod too thin
magnesium powder Low glow tube 12 Glow spiral not properly Battery overload due to excessive
3  -coil technology required, but only one
2 Profile of characteristics does designed current consumption, consequently risk
coil installed not comply with the manufac- of burning of the glow time control unit
turer’s specification contacts: This reduces the service life or
impairs the function
4 Wall thickness not continuous Glow plug blows
5/13 Glow coil mounted in ‚ Short circuit
5 Coil in an inclined position in the glow tube Short circuit inclined position
6 Glow tube not centered, thus no con- The glow plug is destroyed by 14 Cone does not correct fit for Sealing problems, destruction of the
centricity: The glow plug is in an inclined the injection jet and burns the cylinder head cylinder head
position in the antechamber or turbulence
chamber 15 Surface without surface Seizing in the bore
coating
7 Heating rod with hairline cracks Blowing
16 Sleeve is only pushed  oosening and interruption of current
L
8/9 Heating rod tip is filled with not compres- Short circuit, inflation of the supply, loose contact
sed and/or moist magnesium powder glow rod, reduced service life
17  encil length not according to If pencil length is too long: glow plug is
P
10 Round end drilled on, not correctly Blowing manufacturer’s specifications destroyed by the injection jet. If it is too
welded through short: start problems

12
Causes of failure in pencil type glow plugs
In warm and dry weather, a diesel engine will start even if one glow plug is defective and only the
other plugs preheat. In such an event, there will usually be increased pollutant emission and possibly
also knocking during start, however, the driver will not consciously notice these signs, or will not
know how to interpret them. There will be a unpleasant surprise once the weather becomes cold and
clammy, and the first night frost sets in: the “heating contribution” to the diesel engine fails to
function, and the engine will at best start with difficultly and produce smoke– most probably,
however, nothing will work at all. Below is a list of typical damage and the related causes. In most
cases, it will be possible to correct a fault using this diagnostics aid.

HEATING ROD WITH FOLDS AND DENTS

CAUSES: CORRECTIVE ACTION:
Coil interruption due to a) Jump start only at the voltage
a) operation at too high voltage, of the on-board power supply.
e. g. jump start. b)/c) Check preheating system,
b) too long power supply due replace glow time relay.
to a stuck relay. d) Install post-heating glow plugs.
c) impermissible post-heating
when engine is running.
d) use of a non post-heating
glow plug.

HEATING ROD PARTIALLY OR FULLY MOLTEN

OR BROKEN OFF
CAUSES: CORRECTIVE ACTION:
Overheating of the heating rod due to a) Set injection timing point
a) beginning of atomization too early. accurately.
b) coked or worn nozzles. b) Clean or replace injection nozzles.
c) engine failure, e. g. because of piston c) Check fuel jet profile.
jamming, valve breakage, etc. d) Overhaul or replace injection nozzle.
d) dripping nozzles. e) Ensure piston rings can
e) seized piston ring. move freely.

HEATING ROD TIP DAMAGED

CAUSES: CORRECTIVE ACTION:
Overheating of the heating rod due to a) Check injection system,
a) Atomization begins too early, set injection point accurately.
and heating rod and heating coil are b) When screwing in a glow plug,
overheated during this; the heating always comply with the tightening
coil becomes brittle and breaks. torque specified by the vehicle
b) closed annular gap between manufacturer.
plug housing and heating rod;
as a consequence, too much
heat is deflected from the heating
rod, the regulating.

CONNECTING BOLT TORN OFF,

HEXAGON DAMAGED
CAUSES: CORRECTIVE ACTION:
a) Torn off connecting bolt: a) Tighten current connecting nut
The current connecting nut was with torque wrench. Always
tightened with excessive torque. observe specified tightening torque.
b) Damaged hexagon: Do not lubricate or grease the thread.
Use of incorrect tool; the plug b) Tighten plug with suitable torque
is deformed and causes a short socket wrench. Strictly comply with
circuit from the housing to the the specified torque (refer to speci­
round nut. fications of the car manufacturers).
Do not oil or grease the thread.

13
Workshop tips
How to start a diesel engine quickly and reliably
THE PROBLEM THE CAUSE BORGWARNER’S SOLUTION

Fume during start, Glow plug with only one coil, Use BorgWarner 2-coil technology
Smoke production too low temperature glow plug (heating and regulating coil
ensure that a higher temperature is
reached during a shorter heat-up time)

Knocking during Glow plug without Install BorgWarner post-heating

start phase limiting effect and glow plugs for a better and quicker
without heat reserve heat supply

Battery-depleting Glow plug only heats

long start phase up slowly, heat-up time
too long

Difficult and irregular End temperature

running of engine of glow plug too low

Engine only starts Glow plug defective Install BorgWarner GN glow plug
running after several that has accurately been adapted
starting attempts to the engine and the 3-phase glow
system (pre-heating – start heating –
Engine only starts The electrical values of
post-heating)
running with production the glow plugs have not
of unpleasant smells been set appropriately

The glow rod is slightly The wall thickness of the

molten or scaled heating rod is too small
(this is often the case with
cheap glow plugs)

The glow rod is entirely The injection nozzle Replace nozzle holder with BorgWarner
melted is defective replacement nozzle holder assembly

14
 IMPORTANT WHEN
REPLACING GLOW
PLUGS: KEEP TO
THE TORQUES!
Torques
Torques for dismanteling
TIGHTENING TORQUE GLOW PLUG TIGHTENING
Observe tightening torque when disassembling glow plugs. THREAD TORQUE
M8 20 Nm
M9 22 Nm
WHAT MUST I DO WHEN THE TIGHTENING TORQUE HAS M 10 35 Nm
BEEN REACHED? M 12 45 Nm
Under no circumstances should you continue turning – the glow plug might
otherwise break off. Instead, proceed according to the 3-point program:
“Slightly loosen – Warm up – Unscrew”:

1. Slightly loosen: Apply a generous amount of synthetic oil to the glow plug
thread and leave to act, if possible over night, or longer.
2. Warming up: Run engine until it is warm or use a separate cable to supply
current to the functional glow plugs for 4–5 minutes (only
Now inject synthetic oil here.
possible for glow plugs with 11–12 V operating voltage) – the
glow plug will heat up and burn loose.
3. Unscrew: Then try to unscrew it once again and carefully loosen the glow
plug out of the cylinder head with a suitable tool. (Do not exceed
the maximum loosening torque – see table above. Always stop
before reaching the tightening torque, if necessary try once
again by heating up.)
These combustion residues
can be removed with special
After the old glow plugs have been removed, always clean the thread, the conical toolings – like reamers.
seat and the glow plug channel in the cylinder head with suitable tools (see below).
Torques for screwing in
TIGHTENING TORQUE GLOW PLUG TIGHTENING
When screwing in new glow plugs, the tightening torque stated by the vehicle THREAD TORQUE

manufacturer must be observed. M8 8–10 Nm

M9 8–10 Nm
M 10 15–20 Nm
Note: The tightening torque of the connecting nut must also be observed for glow M 12 15–25 Nm
plugs with screwed connection. In particular after baking (coking) between the glow
CONNECTING TIGHTENING
rod and the cylinder head, the cylinder head bore is often soiled by residues from NUT THREAD TORQUE
burning or dirt particles. Such coking can easily and safely be removed from cylinder M4 2 Nm
heads with 10-mm threads. M5 3 Nm

Special tooling (reamer): for a quick and

reliable cleaning of the cylinder head bore
AND THIS IS HOW IT’S DONE:
– P
 rovisionally clean the glow plug bore with a cloth.
– A
 pply grease to cutting area of the reamer and screw it in the cylinder head: GKF01 –
The combustion residues will stick to the grease and will be removed when E6998902897A1
unscrewing the tool.
– T
 he new glow plug can then be mounted without any problem
(please observe tightening torque again!).
– B
 efore installing the glow plugs, grease the shaft and thread areas
with GK grease (GKF01 – E6998902897A1).

15
BorgWarner.
Driving your business.
Now and in the future.

aftermarket.borgwarner.com

BorgWarner Aftermarket Europe GmbH

Morschheimer Straße 12
67292 Kirchheimbolanden, Germany
Tel.: +49(0)63 52 4 03-2300
customerserviceIAM@borgwarner.com