Re: Problem glow plugs - repair..removing /replacing them
I have just done the glow plugs on my peugeot expert van. They are a pain in the arse. I have been putting it off for two years. To do the two that you cannot get to, you have to remove the moving arm that is in the way (don't know part name, but would be throttle arm on a petrol), and also remove the arm stop assembly(vacuum shaped bit with a spring on that the arm rests against when idle.
Now the clever bit. You will need access to a mig welder. Find a socket that will slip over the top of the glowplug secuerly. From memory, I think it is a 12/13mm. Remove socket and weld a 12" length of steel rod with a minimum diametre of 10mm to the side of the socket in an upright fashion. This allows the hole in the centre of the scket to remain clear and also allows the head of the glow plug to poke through it.Then weld an 8" lengh of the same rod across the top of the first rod creating a T bar with a socket welded to the bottom. By welding the T bar to the side of the socket. you create just enough sideways offset to be able to get the socket on the glow plug and clear the obstructions that impede the use of normal spanners and sockets. Use this tool as a normal T bar and simply undo your glowplugs!
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sounds as though the cylinder,s etc are a bit clogged up, try some diesel fuel addative,as with all diesel engines if they do not get long and regular journeys the glow plugs,injectors etc get clogged ,as the engine does not get hot enough to burn these deposits off on short stop start types of journey's . you are possibly looking at replacing the glow plugs but give the addative a try and if possible take for a long drive 2-3 hours at steady highish speed , ok to repeat the addative and long drive once more ,if no improvement will need to go into the repair shop to have the glow plugs seen to at the very least , good luck
I copied this from my GM service manual for 1982 6.2 diesel.
1. If the glow plug relay is not clicking on and off then turn the ignition to the RUN position and connect a 12V test light to ground and touch the pink/black wire in the glow plug relay connector.
2. If the light is off repair the open cicuit in the pink/black wire to the splice.If the light is on then touch the light blue at the glow plug relay connector.
3. If the light is off replace the glow plug relay. If the light is on, disconnect the connection at the thermal controller and touch the black wire in the connector.
4. If the light is off, repair the open circuit in the light blue wire from the thermal controller to the glow plug relay. If the light is on repair open circuit in black wire back to a splice. If no trouble is found replace the controller.
You should also get your hands on this Haynes book. Diesel Engine Repair Manual, part # 10330. Excellent coverage on the 6.2 and 6.5. In it, they say that early 82\'s have a hole at the number 2 hole on the pin connector of the wire harness for the thermal controller. this allows dirt in there and corrodes the pins. Remove the connector and clean thoroughly the pin area on the connection and controller. Seal the hole with some silicone. If things are still acting up, replace the wire harness connector.
you certainly have a problem, checking th glow plugs is easy, 12 volts at the harness to each plug and resistance for the for the plugs, if they are bad it will read open circuit, as for toggling the circuit, bad idea, the original circuit cuts out when the plugs are glowing, without it you willl be constantly burning glow plugs,
should be handy enough just screw out put new one in
if your machine hard to start when heating in the morning ,wait twenty seconds after light goes out then crank it
heater relay still working when heat indicator light goes out
In most cases it is not the relay, although the Glow plugs operate on a reduced voltage, that is where to start checking.
Glow plugs are installed just like Spark Plugs in a Gasoline Engine, use a Long Shank removal socket to extract them, ease them out and make sure they are a snug tight fit on installation
Remove ALL Glow plugs. Set up a 12 or 14 guage wire bared at both ends, that will be long enough to connect to the Positive terminal of the battery, to the opposite Negative.
With the Positive end of the wire connected, take a Golw plug and Press it against the Negative Terminal of the Battery, and at the same time touch the Pos. Wire on to the Center Power terminal of the Glow Plug. If the Plug is GOOD it will start to SMOKE in 3-4 seconds and get HOT. Repeat the procedure with the other 3. If the failure rate is more than 2 out of 4 discard all plugs and install new. If less, replace only the junk ones. If all plugs are Good replace the Power Timer relay on the Vehicle. It is cost effective to check the Plugs first. But at the same time with a Volt Meter check the Power reading at the Glow plug Connection terminal.
Yes you have a defective glow plug relay if you have your owners manual you can find it and replace it, the unit also has a timer on it, if you don't have a book look for the glow plugs and follow the wires from the glow plugs to where they terminate there you will find the relay unit and replace it, to test the glow plugs you remove the wires and test each plug by pulling off the wire and with a cheep ohm meter touch one end to the glow plug and one end to ground if it swings almost al the way over it is ok, if it dos not move then that glow plug is bad. if you find 2 or more bad then replace them all, and if a glow plug has shorted and caused this problem you will have to replace the glow plug relay. Good luck.
Did you hear the one about the Terrano with a charging problem? Just fix it by replacing the thermostat! Seriously - check your temperature gauge does it take ages for the needle to barely get off cold? (and is the heater useless?) The needle should get to just below half way in 2 or 3 minutes. If the thermostat is stuck open, then the engine does not get up to temperature. The glow plug control senses the engine temperature is cold, so the glow plugs stay on for an extended period of time (sometimes 10 to 15 minutes) - short trips particularly in winter, with more headlight driving - the alternator can't keep up with the current being drawn off and from time to time you will end up with a flat battery! A thermostat is cheap, and easy to replace (three bolts and about a half litre of coolant - I pumped the coolant from the top of the radiator, and didn't spill a drop when the thermostat housing was removed). Sure enough, as the engine temperature reached about 50C, the glow plugs turned off.
remove the inner wheel wells or cut it back to get some access its tight that way though i would just remove the two of them its 10& 11 mm on the top sidde just let everthing hang , it is either 5.5 mm or a 7 mm . the speed sensor is in the transfer case for the 4x4 or on theh rear on the trans for 2wd
Your glow plugs are 4 small screw into the block type units that are easy to change out. There is an electrical strip that is connected to the top of each glow plug. take the nut off and remove the wire. Next, use a 10mm deep socket to remove the glow plug itsself. Simply reverse the order. Do not over tighten. there should be a torque spec on them but I don't remember what it is.