1.6TD Glow Plugs

Post by **Caledfryn** » 28 Jul 2008, 13:19

Hello all,

I had a go at changing the glow plugs on my Westy this morning. The back one nearest the exhaust was easyish - a bit fiddly. After that, I decided that I either need to remove the injectors or other bits in order to get at two of them, or have hands the size of a four-year old!

Also, the one at the 'front' of the engine i.e. nearest the back seats, seems to be rock solid. I wasn't too keen on trying brute force in case I made things a worse.

So, my questions are:

1. Any tips or tricks at getting to the two in the middle?
2. Should I resort to brute strength in getting the other one out? Is there any danger it would damage the thread?

Many thanks!

Post by **Titus A Duxass** » 28 Jul 2008, 13:35

Have you tried removing the stuck one when the motor is hot?

My tip for changing the little barstools under the pump - take it to a garage!

I have to do mine soon, bloodyeffinghatethelittlegitsandthetinynuts.

Apparently, it is a good idea to loosen but not remove the little nuts and then use the copper strip to drag them out.

I have also heard that a good ratchet spanner helps, removing the injectors and lines gives more room
(don't forget that you'll need new heat shields under the injectors).

A tip for future replacement:
rather than use the copper strip fit glow plugs 4, 3, 2 with their own leads
(use high temp silicone cover high flex cable and crimps) and connect those three to number one (nearest the seats).
That way you can check each plug individually and removal is easier.

Post by **ringo** » 28 Jul 2008, 14:19

I did a search and found this link:

https://club8090.co.uk/forum/viewtopic.p ... glow+plugs

I bought the glow plug spanner and i never use it - its too easy to round the glow plugs off.

Take off the injector pipes before doing it - saves you a lot of hassle....

Ringo

Post by **redstar** » 28 Jul 2008, 18:33

Yes, injector pipes off are a good idea! the only one that appears difficult in any way is the second one from the rear of the bus... I seem to remember that you need to pop that one in first, and with the nut wound down the thread as it catches at the top...... think that was the reason

then again could be my memory again!

Post by **Caledfryn** » 28 Jul 2008, 19:58

Titus A Duxass wrote:Have you tried removing the stuck one when the motor is hot?

That occurred to me tonight after I'd got back from shopping in it. The heavens then opened and I haven't had a chance to try it.

I've found a flexi- screwdriver with a socket end undoes the 8mm nut on the second one from the rear, so I reckon with a bit of fiddling I can sort that one. As for the final and most difficult one, well, I'll have to have another look. Is taking the injector pipes out a big deal ? Or is it just a case of loosening the nut and moving the things out of the way ?

ringo wrote:I did a search and found this link:

https://club8090.co.uk/forum/viewtopic.p ... glow+plugs

Thanks for that link, ringo, I think I just searched for glowplugs and didn't find anything!

Post by **redstar** » 28 Jul 2008, 20:13

no big deal m8, popem off, then replace when you are done. sometimes you get an air lock in the injector, but easily sorted with, i think a 17mm open end. you can tell with the engine 'tone' and this will alter after you slack them a smidge if there is air in there...... any probs there is more than enough knowledge in the ranks of 80-90

Post by **Caledfryn** » 30 Jul 2008, 10:56

Back again!

Well, I finished changing the plugs yesterday and was rather disppointed to see that they all looked pretty unscathed when I got them out!

Went to start the van more in hope than expectation and low and behold, starting doesn't seem any better. Still takes and age to 'catch' and when it does, it's accompanied by a big blast of smoke.

Anyone got any other ideas about why it might be reluctant to start?

Post by **Titus A Duxass** » 30 Jul 2008, 11:12

Is the main glow plug fuse still intact?
Is the glow plug relay working? You should here it clunking.
Is power getting to the glow plugs?

Post by **BIG D** » 30 Jul 2008, 17:20

Had the same problem mine just wound and wound changed the glow plugs 3 houra later and a bad back!!! changed the relay in a box on the left of engine still problem there then realised that the in line fuse in front relay had blown,it could be that the new plugs have more power and have beown that fuse i bypassed it and hey presto it worked,hope this helps,dave

Post by **Caledfryn** » 30 Jul 2008, 18:31

Cool. More things to try!

I'll get there in the end.

Thanks

Post by **Simon Baxter** » 31 Jul 2008, 09:07

Pull the injector pipes and injectors out.
use a 8mm and a 12mm ratchet spanner.
Use new flame traps for your injectors upon refitment.
If you know what you are doing, have all the tools and the injectors aren't stuck in then it will take 30 minutes.
DO NOT SKRIMP ON THE FLAME TRAPS or you injectors won't last 2 minutes.

Post by **Titus A Duxass** » 31 Jul 2008, 10:29

Simon - do you have a recommend make of ratchet spanner or least some details of the head/neck bend angles?

I have tried an el cheapho ratchet ring and it was pants.

Post by **ringo** » 31 Jul 2008, 11:05

Titus A Duxass wrote:Simon - do you have a recommend make of ratchet spanner or least some details of the head/neck bend angles?

I have tried an el cheapho ratchet ring and it was pants.

Me too - and it wasnt that cheap (£10)... I dont even bother with it now.

Personally, i can get away with just removing the injector pipes and not the injectors.

Ringo

Post by **airhead** » 31 Jul 2008, 12:14

I had a similar problem to this with my Syncro. Adjusting the valves and pump timing sorted the problem out. Remember that most of these engines have bucket and shim tappets. Take off the cam cover on top of the engine, measure the valve clearances, and do some maths to see if you'd get away with swapping some of the shims around to get them back into tolerances. Otherwise you can buy the shims you need when you know what size you need.

Post by **kit** » 31 Jul 2008, 17:39

Would air in the system eventually work itself out?

I can get away with just removing the pipes as well Ringo, must have dainty hands