VW/Audi Glow plug cable socket repair/fix TPU/TPC

When replacing the glow plugs on my VW/Audi, all of the glow plug socket ends just crumbled and fell apart, this seems a common issue for these cars with age, you can buy repair kits that you have to cut and splice a new end to the existing loom, but I had to get the car going again on the weekend and there were no shops open that stocked a replacement, plus they are very expensive!

The part number is 07z971782 for the plug lead this will fit and think they are common across many brands such as AUDI, CUPRA, SEAT, SKODA, VW.

So I designed this cover that encapsulates the original inner plastic sheath which clicks onto the end of the glow plug and the top part of the lead which had not deteriorated - see pictures on how it fits.

I used 95A TPU as it needs to be flexible to fit around the plug lead and held in place with 2x 3mm cable ties, TPU should hold up to temps of around 100 degrees before softening at all which should be more than enough for around the glow plugs, ideally if you have TPE/TPC or another flexible high temp resistant material that might be better, but TPU 95A seems to been doing the job really well for the last 4 months with the car in regular use with zero signs of melting or deforming, even the cylinder closest to the the turbo.

It is designed so that when you add a cable tie it locks in place and will not come off unless you cut the tie, so should have no issue grabbing the cap end and popping them off the glow plugs if needs.

I have included a few different versions in the profile, with and without a flange and also one printed at an angle to help stop the layer lines tearing during fitting, I think my TPU needed drying so had issues with layer line separation further up the print when printed on it's base, the angled print helped this considerably.

I will caveat that you use this at your own risk, printed materials in an engine bay always makes me uneasy, but saying that it has worked perfectly for me for the last few months made from 95A TPU and until I can find genuine replacements which are still out of stock nearly everywhere I have looked.

If this print was useful please leave a comment and support me with a boost would be great!