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Beru glow plugs Faster, more reliable diesel cold starting, even at low temperatures

Beru – the world’s leading producer of glow plugs

BERU Aktiengesllschaft Mörikestraße 155 D-71636 Ludwigsburg Telephone ++49-71 41-132-0 Fax ++49-71 41-132-390 E-Mail: [email protected] Perfection

www.beru.com Bestell-Nr. 5 100 001 018 · Printed in Germany 15.12.03 built in What can we expect from a modern glow plug?

The diesel – drive technology of the future The Beru glow plug type code: the short designation reveals the technology

Modern diesel engines deliver high power and torque, yet are quiet running and economical. It´s no wonder that Conventional glow plugs (code: ”GV”) only glow before start- more and more motorists are opting for diesel powered ing. The glow plugs which Beru offer with the code ”GN” . Today, two out of every five new registrations have are post-heating glow plugs. This means that they glow: diesel engines and the trend is upward thanks to innovative 1. before starting (as ”quick-start” glow plugs they are technologies. And more and more vehicles are leaving the only required 2–5 seconds), factory fitted with glow plugs from Beru, the diesel cold 2. during starting and start specialist and world´s leading glow plug manufacturer. 3. after starting (up to 300 seconds depending on the system).

The innovative glow plug ensures that the A diesel cannot run in cold conditions reaches the ideal ignition temperature faster. without glow plugs is therefore more complete, the dreaded ”diesel knocking” in the start phase is prevented. Modern glow systems use almost exclusively such post-heating glow plug types. Diesels are self-ignition engines, at least most of the time. At low temperatures and in winter the diesel needs a T 0C ”heat boost” so that the fuel can ignite. This major task 1050 is undertaken by glow plugs. Modern glow plugs should 850 fulfil a series of other functions too.

High quality glow plugs are kind to both engine and environment! t Pre-heating Startglow Post-heating 2–5 Secs. approx. 2 Secs. approx. 300 Secs. Defective or cheap glow plugs can often not carry out the tasks they were designed for. Beru glow plugs are Every glow plug that leaves the Beru factory has under- long-lasting and fulfil all requirements because they are gone functional testing. The fact that very few plugs fail perfectly adapted for their role. As the world’s leading during testing is an indication of the continual quality producer of glow plugs, Beru has long been involved in assurance through every stage of production. You can rely engine development within the motor vehicle industry. on Beru glow plugs. And that pays dividends: Diesel fast-start in 2–7 seconds, reliable starting down to minus 30 °C, smooth, engine- friendly warm-up, up to 40 % less soot emission during warm-up phase with post-heating plugs and long life. That’s what can be expected of a Beru glow plug!

2 3 Even glow plugs get old! Which diesels can be retrofitted?

The life span of glow plugs will vary depending on regular- The simply to fit Beru SR sets allow even older vehicles ity of use and climatic conditions. Regular cold starting to benefit from the environmentally friendly Beru will cause glow plugs to age faster. Generally, by the time 3-phase glow system concept – bringing them back up the unsatisfactory operation of the glow plug is noticed, to state-of-the-art. it is too late: At the first un- expected frost the diesel starts Short pre-heating periods and post-heating of up to 180 really badly, knocks loud and seconds – that is environmentally and engine friendly! produces great clouds of smoke. Below minus 10 °C, it may not start at all. High time indeed to replace the glow plugs; preferably the whole set.

Our tip: Ask your workshop to test the pre-heating sys- tem with a glow plug quick-tester at the next servicing. It takes only a few minutes, without removal of plugs. Environmentally friendly retrofit sets for diesel passenger cars Type Order No. Contents Application Make your diesel environmentally fit! SR-Set 002 0 120 000 002 GV 626 x 4 Mercedes (model W 115) Beru has retrofit sets for many vehicle models, to make Only for models with pull-switch and heater that used diesel more environmentally friendly. These sets warning lights as pre-heating. SR-Set 028 0 120 000 028 GN 857 x 4 Audi 80 diesel –7.91** Volkswagen include new generation glow plugs and a modified glow Golf/Jetta/Passat/Bus diesel 7.91** phase control unit which can simply replace the existing On 5/6 models add 1 or 2 GN 857 system. The benefit of these retrofit sets is that the con- SR-Set 030 0 120 000 030 GN 918 x 4 Ford Fiesta, Escort, Orion 1,6 ltr. all models trol unit facilitates glow plug preheating for up to 3 min- Escort, Orion 1,8 ltr. all models utes after starting. This ensures that the fuel combustion SR-Set 031 0 120 000 031 GN 954 x 4 Opel Ascona C 1,6 ltr., Astra 1,7 D (not turbo) 10.91–08.94***, Kadett D 10.80–09.84, Kadett E is more complete and quieter during the warm-up phase. 10.84–09.91***, Vauxhall Astra all models The engine starts quicker, smoother and with up to 40 % SR-Set 032 0 120 000 032 GN 954 x 4 Citroën BX 17 D, BX 19 09.83–12.87 XUD/ less soot. That benefits the environment. CX 25, 2,5 ltr. 07.82–12.92 M 25–660, Visa 04.84–03.91, 161 A, Xantia, ZX 1,9 ltr. 03.93– XUD/C 15, C 25 07.86– XUD/C 32, C 35 2,2 ltr. B 22 Fiat Ducato 10, 14, 18 Diesel + TD 2,5 ltr., What now: When the time comes to replace the glow Peugeot 205 D 10.83– XUD, 305 D 11.77–10.83 XID, 305 D 10.82–07.90 XUD, 309 D 06.86– XUD, 405 D plugs, why not upgrade to the environmentally friendly 03.88– XUD, 504 D 07.84– XD, 505 DO 09.79–12.93 retrofit set. Furthermore: This modern glow plug technol- XD, 604 TD 02.79–06.86 XD/J 9 D 05.81– XD Talbot Express, Horizon, Solara 11.78– XUD, Tagora ogy from Beru is fitted as standard on many new vehicles. TD 09.81–06.83 Adapter cable AG 001 is required for control units which are fitted with 5-pin minitimer plugs. SR-Set 039 0 120 000 039 GN 909 x 4 Mercedes Benz W 123 D, W 126 D (USA), GR 049 x 1 W 201 D → 01.89, G 460/461 D 01.89, Exhaust gas clouding 207 D, 209 D, 307 D, 309 D, 407 D, 409 D, without and with 507 D, Sprinter 212 D, 312 D, 412 D environmentally SR-Set 040 0 120 000 040 GN 858 x 4 Mercedes Benz W 124 D (2-Ventiler), W 201 D friendly retrofit sets GR 049 x 1 02.89 →, G 460/461 D 02.89 →, C 200 D, 208 D, 210 D, 308 D, 310 D, 406 D, 410 D, 508 D, Sprinter 208 D, 308 D, 408 D, Vito 108 D, 51 % up to now 32 % with SR sets 110 D, V 230 TD Ssang Yong Musso all models

4 ** 1.89-7.91 only vehicles without GZA-pre-heating *** not ISUZU engines 5 Causes of sheathed glow plug failure

A diesel engine will start in warm and dry weather even if Heating rod melted, melted through or broken Tip of heating rod damaged a glow plug is defective and only the other plugs pre-glow. Although the start is usually accompanied by an increased Causes: Possible remedies: Causes: Overheating of the heating rod due to a) Set injection time precisely Overheating of the heating emission of pollutants and sometimes shuddering, the driver a) Premature start of injection b) Clean injection nozzles rod due to will not consciously notice these signs or may be unable b) Nozzles blocked or clogged with soot c) Check jet profile a) Premature start of injection, to interpret them correctly. The nasty surprise then comes c) Engine damage, e.g. due to which overheats the heating when it is cold or damp and the first night’s frost arrives: corrosion or valve breakage, etc. rod and heating coil; the d) Dripping nozzles heating coil becomes brittle The ”source of heat“ in the diesel engine no longer func- e) Piston rings blocked or stuck and breaks Possible remedies: tions and at best it will start poorly and smoke – although b) Closed ring gap between the plug a) Check injection system, set the it is more probable that nothing will start. The following housing and the heating rod; injection time precisely indicates typical damage and lists the various causes. This too much heat dissipates out b) Adhere to the tightening torque of the heating rod as a result, specified by the manufacturer diagnostic aid guarantees a speedy remedy in most cases. the regulating coil remains cold when screwing in the glow plug and allows too much current pass into the heating coil, which overheats

Heating rod with folds and dents

Causes: Break in the spiral caused by a) Operation with excessive Connecting bolt broken, hexagonal bolt damaged voltage, e.g. with a aid b) Current applied too long by Possible remedies: Causes: Possible remedies: suspended relay a) Use starter aid with a) Break in connecting bolt: The a) Tighten the current connecting c) Forbidden afterglow while 12-Volt on-board network current connecting nut was nut with the torque spanner; engine is running b)/c)Check pre-glow system, tightened with excessive torque adhere to the tightening torque d) Use of a non-afterglow-com- replace glow time relay b) Damaged hexagonal bolt: b) Tighten the plug with a suitable patible glow plug d) Install afterglow- Use of incorrect tools; the de- torque socket spanner; adhere compatible glow plug formation of the plug creates exactly to the specified tightening a short-circuit between the torque (this can be seen in vehicle housing and the round nut manufacturer regulations)

closed up

normal 6 7 8 Heating element tip damaged Correct glow plug replacement

Important when replacing:

Check type designation! 1 Installing glow plug with torque wrench: Connection stud Ensure to observe vehicle manufacturer’s specifications. If the incorrect glow plugs are fitted, the consequences Caution – observe maximum torque settings: M 8 threads: Round nut can be severe for the engine operation and the glow plugs 10 Nm, M 10 threads: 12–15 Nm, M 12 threads: 20–22 Nm. themselves. Insulating washer O-ring seal Therefore: Ensure that the replacement glow plugs are 2 Installing glow plug when torque wrench not available: Plug body the correct type. The Beru application lists provide details Screw glow plug into until finger tight. Then on which glow plugs or environmentally friendly retrofit turn down by approx. 30° with a suitable tool. sets are suitable for which vehicles. Details are also pro- Our tip: Seal vided of which third party glow plugs can be replaced by To carry out the task safely and accurately we recommend Beru plugs. Every Beru glow plug is marked with a 10-digit the use of a torque wrench. Beru number and a voltage value. These can be clearly seen on the plug body. 30°

Installation thread Plug bodies with 10-digit number

Tighten glow plug approx. 30°

Annular gap

Glow tube Two important rules when replacing glow plugs: 3 Tightening power connection nut: The maximum torque setting for the power connection Regulating filament 1. Only install glow plugs in OE qualitiy, as supplied by Beru. nuts must not exceed the following values: M 4 threads Insulating filling 2. If the manufacturer specifies post-heating glow plugs, max. 2 Nm, M 5 threads max. 3 Nm. If glow plugs have only use glow plugs with the designation ”GN”. plug connections, check these for corrosion. Heating filament Ensure correct torque settings of glow plugs and power connection nuts!

When replacing glow plugs, three points in particular are Economy tip: Replace glow plugs as sets! Note: Plugs are difficult to access on certain engine to be observed: Experience shows that glow plugs reach their maximum models. Replacement of plugs may require partial removal 1. Under no circumstances must contamination around wear levels in quick succession, and if connection lines and reinstallation of pressure lines. If you plug hole fall into . and power rails are already removed it would be more are not familiar with diesel equipment, it is recommended 2. Glow plugs must be tightened to the correct torque. economical to replace the complete set, rather than have that replacement of glow plugs on your diesel engine be 3. Power connection nuts must be tightened to the to replace other plugs individually a short time later. carried by a specialist workshop. correct torque.

9 10 11 Innovation in Diesel Cold-Start Technology: Original Beru Quality – the Beru Instant Start System (ISS) What’s Behind It?

More and more diesel commercials are being fitted with The quality of Beru sheathed glow plugs begins in the the Beru ISS diesel instant start system as standard. This very earliest stages of product and process development, innovation creates opportunities for the diesel engine while systematic project management is used to create a that were once the preserve of petrol engines – starting product that is ready for mass production. speed and emission reduction being two prime examples. The system consists of optimised glow plugs and an elec- The sheathed glow plugs are manufactured in over 20 tronic control unit. fully automated production and assembly operations, with each operation being continuously monitored. Once The control unit regulates the voltage of each individual assembled, each plug is function tested. glow plug. This achieves not just an extremely short time of two seconds to starting readiness – it also allows con- The result is a product of the highest quality that meets trolled post-heating and intermediate heating. The tem- the demands of motor manufacturers. Motorists too perature of the glow plug is matched perfectly to the ultimately benefit from this quality. engine’s operating point. For the motorist, this means immediate, smooth idling, a clean load takeup and hence lower emissions. All Beru plants world-wide are ISO 9001:2000 certified. In addition, all German factories hold the QS 9000, VDA The features of the Beru ISS: 6.1 and ISO/TS 16949:2002 certificates and the environ- ■ ”petrol-engine” key start down to 25 °C below zero mental certificate ISO 14001. ■ just 2 seconds preheating time ■ controllable temperature for pre, post and intermediate glow ■ smooth running engine ■ smooth idling and instant load takeup ■ minimised pollutant emission ■ on board diagnosis compatible

Motor manufacturers who fit their vehicles with Beru ISS as standard include VW, Audi, BMW, Seat, Mercedes-Benz and AMG.

Genuine Beru Performance- quality products feature in the OE of all leading inter- enhanced glow plugs and an – the national automobile manufacturers. components of the Beru ISS Diesel Instant Start System. 12 13