I changed a few glow plugs and tracked down a rattle in the front passenger door on my 87 TD. I learned A LOT!

1) The #1 glow plug is really easy to get to/replace on a 603 with a turbo, but the other plugs aren't (#2 is only slightly more difficult, the rest are a PIA). When the #1 glow plug is found to be the source of poor starting, don't go overboard and replace all the other ones (on this engine anyway).

2) When tightening the glow plug connector, make sure to use something to hold the connector from spinning around and touching the intake manifold. If you don't, it will probably ground out and blow your relay fuse when you try to start it.

3) Old plastic vacuum lines are brittle and can break easily. Especially the brown one that is right behind the glow plug relay cover, which incidentally gives vacuum to your dash (car won't turn off, vent pods stuck)

And most importantly: 4) When drilling through your door panel so that you can use some screws to secure the armrest to the panel (replacing the crappy melted plastic that always breaks), don't put your hand on the other side where you can drill into your hand should you drill through the panel.

I drilled almost completely through my finger, it hurt, but didn't cause bone damage. When I was leaving the doctors office today, I blew my GP relay fuse, and in examining the fuse I broke the vacuum line that feeds the dash. What a weekend.

I really needed to share this with somebody (other than my wife, who doesn't always want to hear about GP relay fuses and stuff), it was too crazy to keep all to myself. Hope you don't mind

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-justin

1987 300TD, 1987 300TD
2008 R32, 2000 Passat Wagon