Is the glow plug relay behind the fuses? If so which one is it? If I have to replace the glow plugs is it easier if I remove the intake manifold? I hate to break one of those in the head. Does penetrating oil before removal worth trying,and finally where and what kind of glow plug should I use?
Thanks
Sixto the clunk I felt must have been the shifting of the tranny, found the broken vacuum line fixed it and solved one problem.

Wondering if I should just replace all the glow plugs...
If I remove all the injectors can they be cleaned? 115,000 miles
carmen

Glow plug relay is on the driver side wheel well, take the top off and check the strip fuse. It will be easier to replace glow plugs if you take the intake off but can be done with it on, I would use Bosch plugs.

This is pretty much a gasser support site. You could probably get more technical advise on the diesel forum...good luck!

Is the glow plug relay behind the fuses under the black cover with the other relays? If so which one is it? If I have to replace the glow plugs is it easier if I remove the intake manifold?What is involved in removing the intake manifold? I hate to break one of those plugs in the head.Read on the forum that removing them with a hot motor eases there removal? Does penetrating oil before removal worth trying,and finally where and what kind of glow plug should I use?
Thanks
Sixto the clunk I felt must have been the shifting of the tranny, found the broken vacuum line fixed it and solved one problem.

Wondering if I should just replace all the glow plugs...
If I remove all the injectors can they be cleaned? 115,000 miles
carmen

Sorry I am new to the forum and still trying to locate where things are.

You're still in the Tech forum. Try Diesel Discussion.

The glow plug relay is on the driver fender behind the ABS pump. It's a black box about 4" by 4" by 1.5". There's a plastic cap on the relay so you won't see the connections. The cap just pulls off though you have to navigate the tight quarters. The glow relay has a live battery connection so be careful with metal tools, or better still, disconnect the battery. There is an 80-amp strip fuse in the relay. Make sure that fuse is intact. Best to remove it and make sure it comes out in one piece. Sometimes it breaks so cleanly that it looks intact. There is a big 6-pin connector and a small 4-pin connector. The big 6-pin connector has the wires to each glow plug. The connector sockets are numbered corresponding to the engine cylinders.

Glow plugs don't have a service life per se. Replace them when they go bad or when they're accessible, not because of age, miles or number of cycles. Get Bosch glow plugs through the Buy Parts link above. Autolite don't last.

If you have to replace glow plugs and this is the first time, it makes sense to remove the intake manifold. There are 12 bolts that take a 6mm hex tip holding the manifold to the cylinder head. It takes a long hex tip with a wobble tip. First the crossover pipe has to come off. There are 2 bolts that take a 5mm hex tip between the crossover pipe and intake manifold. Put a rag under the junction to catch the gasket that might otherwise slip between the block and IP. I've yet to see a gasket that wasn't reusable. There is a further bolt and nut and bolt pair holding an angle bracket at the turbo end of the crossover pipe. Remove those as well. The horizontal bolt has a nut on the opposite side. You'll have to reach it by feel with a 10mm wrench. There is a big green o-ring holding the crossover pipe to the mixing pipe. Wiggle the crossover pipe off the o-ring. I've yet to see a big green o-ring that wasn't still round and supple even after 300K miles of service. All o-rings should be this tough. Then release the injector lines at the IP and injectors. I use a 14mm wrench but it's more appropriate to use a flare wrench or the special crow's foot socket. What's left are bits and pieces like the boost signal line, overboost pressure sensor wire and various wire clamps to remove before the intake manifold comes loose.

Now is a good time to check that the injector line clamps are in place and intact. I'll leave that for another thread

Sixto
87 300D

First of all I would like to thank all for the expert advice you have given me this past week...It is really appreciated.
Wondering if replacing my glow plugs could solve blue smoke when starting.It does go away after the car warms up but it also has become noisy.
Tried to test the glow plugs but cannot locate the relay..Is it in the box behind the fuses with all the other relays? Was told it was on top of a strip fuse but still cannot find it.
Ordered Bosch glow plugs will give changing them a try.
Removed the crossover pipe atop the valve cover could not believe how much soot was inside, assume the intake manifold will look the same.
How difficult is it to check IP timing and if off how to correct?
thanks
Happy New Year to all of you
Carmen

Sixto can I e-mail you directly? I noticed smoke coming out by the turbo area when cold starting
What is the term nailing mean? Is it the clatter I am hearing and does this usually caused by a bad injector?
carmen

There is a private message feature if you want to reach me directly. Click my name at the heading of this post.

Smoke from the turbo area sounds like an exhaust leak. There is a junction in the exhaust manifold between the #1 and #2 runners and the rest of the intake manifold. There is a pipe covered by a metal accordion section. I've heard of leaks from that junction. There aren't many other sources of smoke on that side of a cold engine. Is the hose from the valve cover to the turbo air inlet hose intact? You might get some smoke from the forward part of the engine if that ventilation hose is broken or not fitted properly.

Most of the clatter I hear is worn belt tensioner dampers, tired or dirty valve lifters and improperly restrained injector lines. The latter is more of a clicking. If an injector is making noise, the noise usually goes when you loosen the injector line. If you find a culprit, swap injectors with another cylinder to see if the noise moves with the injector. Don't forget new heat shields when you refit injectors. Nailing sounds like pounding a big nail into concrete.

Sixto
87 300D

I have read that it is possible to change the glow plugs without removing the intake manifold. I can tell you forget it it is impossible, make life easier, listen to Sixto, I removed the intake manifold and it was a snap. First I tried w/o removing it and it was a joke.
thanks again Sixto u definitely know your stuff.


Now the corr pipe/sleeve on the exhaust.
Carmen