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Changing the Glow Plugs
1.9 Diesel
Freebo
28-06-2012
***Make Sure your engine is cool before doing this***<br />
<br />
First of all you need:<br />
-Replacement Glow Plugs<br />
-9mm deep socket (and long reach attachment)<br />
-5mm allen key<br />
<br />
1. Remove the plastic cover from the top of the engine<br />
Old 16-09-2017   #15
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Re: Changing the Glow Plugs

Thank you, that's what this Forum is all about....!!
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Old 18-09-2017   #16
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Re: Changing the Glow Plugs

So, I've succesfully removed 3/4 glowplugs, but obviously the last one snapped just below the threads of the glowplug. I've managed to attach a screw inside the plug and I am able to pull the screw with a grip tool, but the glowplug doesnt want to move an inch

I will spray some carburator spray in there and see if it helps. If anyone has any suggestion, it would be highly appriciated!
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Old 18-09-2017   #17
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Re: Changing the Glow Plugs

Use carb. spray to disolve carbon, and after that, use a lot of (real) penetrating oil ( not the blue WD40...).
Turn/twist it slowly both sides, and hopefully it will come out in the end...
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Last edited by Peter Pick-Up; 18-09-2017 at 19:51.
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Old 18-09-2017   #18
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Re: Changing the Glow Plugs

Quote Originally Posted by Peter Pick-Up View Post
Use carb. spray to disolve carbon, and after that, use a lot of (real) penetrating oil ( not the blue WD40...).
Turn/twist it slowly both sides, and hopefully it will come out in the end...
I will try that for sure! I'll cross my fingers and give an update if it works or not
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Old 19-09-2017   #19
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O'boy,. Now it's gotten even worse. I was impatient and tried doing it this way, but this thing broke off too (not sure what the English word for it is).

Don't even wanna think what it will cost to remove the cylinder head by a workshop.
I'm gonna try and drill a hole in the plug and make threads, then try and force it out with a hex head screw. Something like this https://www.google.se/amp/www.instru...famp_page=true

A word of advice to anyone here thinking about replacing their glowplugs themself - don't! Leave it to a mechanic.
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Old 19-09-2017   #20
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Re: Changing the Glow Plugs

[QUOTE

A word of advice to anyone here thinking about replacing their glowplugs themself - don't! Leave it to a mechanic.[/QUOTE]

Did you blow away debris with compressed air first?
And did you soak the plugs with penetrating oil and carb. spray for at least a week, like we advised you?
If not, you pay the toll, I'm afraid....the head has to come off, don't risk metal parts falling into the cilinder, ruin the engine at first start up.
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Old 19-09-2017   #21
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I used some compressed air. Let some rust removal spray (oxid cleaner) sit for 2-3 days. I did this while the plug was halfway as well. Including carburetor spray. And while the engine was hot. But I didn't want to spray too much, due to the fact it's very flammable stuff (hot engine).
My theory is that this plug had been defective for a while, building up carbon and thus being more stuck. Possibly already having a crack, too.

anyway... if I suck up any metal debris with a vacuum cleaner after drilling, that should eliminate that risk. There is still about 80% of the plug left in the cylinder head.
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Last edited by Fiatswe; 19-09-2017 at 10:36.
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Old 19-09-2017   #22
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Re: Changing the Glow Plugs

OK, good luck, keep us informed!
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Old 22-09-2017   #23
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Re: Changing the Glow Plugs

So, thought I'd give an update how it went. The "easy out" that I broke inside the glowplug, seems to be nearly impossible to drill out. Extremely dumb of me to put it in there, it made the situation 100x worse.
I've called workshops and they werent even willing for the task to remove the plug from the cylinder head, while it's off the car. They said they've tried it before and that it's not worth the time it would take.
I drove the car to a friendly local mechanic. No success there either trying to drill the easy out. He is willing to remove the cylinder head and remove the plug, but it would probably cost about $12000 usd at least.
I've been driving the car for a few days now. It has 3 new glowplugs, plus the one broken/stucked inside the cylinder head. I'd say the car starts better now and the engine runs great. Ive tried driving the car at 4000 rpm, just for a few seconds. Was hoping this would shoot out the plug, but it seems to be "glued" in there.
I know it isn't ideal to drive the car like this, but right now Im not sure what we will do in regards of this problem. The timing belt needs to be replaced within 1-2 years. Taking the head off at the same time, would sort of "smash two flies at once". Since it's necessary to remove the belt when removing the cylinder head, anyway. A timing belt replacement costs about $500 where I live.
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Last edited by Fiatswe; 22-09-2017 at 13:25.
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Old 22-09-2017   #24
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Re: Changing the Glow Plugs

Not ideal to have only 3 glowplugs working, especialy with cold winter weather nearby...
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Old 23-09-2017   #25
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Re: Changing the Glow Plugs

Quote Originally Posted by Peter Pick-Up View Post
Not ideal to have only 3 glowplugs working, especialy with cold winter weather nearby...
yeah you're right not sure how it will act when it's -20 and what effect it will have in the long run on the engine. Will be interesting, I guess. But it's my mothers car and she won't let me try and drill it out, thinking it would get worse. She thinks the car is "fine" now.
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Old 30-09-2017   #26
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Re: Changing the Glow Plugs

YEES! I eventually managed to get the broken plug out! I convinced my mom that we had to get it out, especially since the winter is coming.
I bought a dremel with an extensior and tried everything available in that kit. Hoping that I would be able to grind or drill that easy out down. But nope! that thing is HARD!

Anyway.. I kept driving the car and suddenly the plug had popped up about 1-2 cm! now I was actually able to grab it with a grip tool, but it was still stuck there like glue.
I sprayed some more "oxid cleaner" and carbon spray around the glowplug. Kept driving it warm all day, reving it more than usual. It popped up another 1-2 cm. Eventually I was able to twist and turn it back and forth, up and down - til it came out in one piece. Felt like winning a lottery!

Ironically I think the vibration from the dremel must have shaked it loose, along with the carbon spray.
The car runs and starts great, has 4 new glowplugs and the dashboard warning is gone. I am superhappy that I managed to save our lovely Bravo without having to remove the head.
Lessons learned though! I should have been more patient with the one being stuck, for sure.
This is not a hard DIY - but you have to be EXTREMELY careful and patient. Make sure the engine is at fully operating temperature (hot) while removing the plugs. The guide here says it should be done when the engine is cold but this is incorrect. Someone should change this.
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Last edited by Fiatswe; 30-09-2017 at 11:20.
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Old 30-09-2017   #27
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Re: Changing the Glow Plugs

YEES! I managed to get out the broken plug out, eventually. I convinced my mom that we had to get it out, especially as the winter is coming.
I bought a dremel with an extensior and tried everything available in that kit. Hoping that I would be able to grind or drill that easy out down. But nope! that thing is HARD!

Anyway.. I kept driving the car and suddenly the plug had popped up about 1-2 cm! now I was actually able to grab it with a grip tool, but it was still stucked there like glue.
I sprayed some more "oxid cleaner" and carbon spray around glowplug. Kept driving it warm all day, reving it more than usual. It popped up another 1-2 cm. Eventually I was able to twist and turn it back and forth, up and down - til it came out in one piece. Felt like winning a lottery!
Ironically I think the vibration from the dremel must have shaked it loose, along with the carbon spray.
The car runs and starts great, has 4 new glowplugs and the dashboard warning is gone. I am superhappy that I managed to save our lovely Bravo without having to remove the head.
Lessons learned though! I should have been more patience with the one being stuck, for sure.
This is not a hard DIY - but you have to be EXTREMELY careful and patient. Make sure the engine is at fully operating temperature (hot) while removing the plugs. The guide here says it should be done when the engine is cold but this is incorrect. Someone should change this.
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Last edited by Fiatswe; 30-09-2017 at 13:42.
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Old 31-01-2021   #28
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Bit of a thread resurrection but I just changed the glowplugs in our Doblo (1.6 multijet 2011) and it was an absolute breeze thanks to the advice here. Soaked in plus gas regularly from Wednesday, bought Bosch plugs, correct 9mm socket, warm engine and removed using a torque wrench to prevent over doing it. Fitted new plugs using ceramic grease. Was so straightforward I thought I'd done it wrong. Thank you all
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Old 31-01-2021   #29
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The old plugs.
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