Technical Replace Glow Plug Relay

[donaldinho]

Hi folks,

I have a 1999 Ducato 2.5tdi.

Glow plug light flashing and annoying click coming from what I have been told is the relay! Van starts fine.

Is this a part I can replace myself? (moderately competent)

The internet tells me I have an older cylindrical/canister type (see attached), so I'm not sure if these are available?

Any advice would be greatly appreciated!

Thanks, Donal

 

[bugsymike]

Hi folks,

I have a 1999 Ducato 2.5tdi.

Glow plug light flashing and annoying click coming from what I have been told is the relay! Van starts fine.

Is this a part I can replace myself? (moderately competent)

The internet tells me I have an older cylindrical/canister type (see attached), so I'm not sure if these are available?

Any advice would be greatly appreciated!

Thanks, Donal

Not sure if I recognise yours from the photo, I had a 1997 2.8 idt Ducato and several of those engines in Iveco Daily's.
Providing you can still get your type relay it should just be a case of unplugging and unbolting from it's mounting and replacing with the new unit if that is the issue.
If your type no longer available then you may need to check the wiring to convert to the other type.
From what I can see in your photo it looks like you unscrew the round plastic bit and then the wiring plug should drop out, clean the connections with switch cleaner and fit in new unit.

 

[donaldinho]

Not sure if I recognise yours from the photo, I had a 1997 2.8 idt Ducato and several of those engines in Iveco Daily's.
Providing you can still get your type relay it should just be a case of unplugging and unbolting from it's mounting and replacing with the new unit if that is the issue.
If your type no longer available then you may need to check the wiring to convert to the other type.
From what I can see in your photo it looks like you unscrew the round plastic bit and then the wiring plug should drop out, clean the connections with switch cleaner and fit in new unit.

Thanks a mill for response.

I am guessing this is the relay but not having much luck in figuring out how to remove. There is a screw into a metal place at front that I can access but I can also feel one in behind with no way to access. Also struggling to disconnect the wiring connection at bottom of relay.

 

[bugsymike]

Thanks a mill for response.

I am guessing this is the relay but not having much luck in figuring out how to remove. There is a screw into a metal place at front that I can access but I can also feel one in behind with no way to access. Also struggling to disconnect the wiring connection at bottom of relay.


View attachment 484582

Can you remove the whole bracket and then work on it as the screws look a bit rusty.
Are you sure it is faulty, have you put a volt meter on the glow plugs and had someone turn ignition on with your hand or ear by that relay to check that it is the one clicking and to see if that stops at the same time voltage stops at heater plug?
Looking at the photo of the plug it may be you have to slide a thin screwdriver up the plug to release a catch so plug come off. As a clue sometimes the vehicle will use similar plugs elsewhere on the vehicle so you can see how they release. It looks a little like a Bosch type that uses that sort of plug, just go gentle others it will not lock on with new relay. Also spraying connector with WD40 and pushing it together slightly before trying to release sometimes helps.

 

[Communicator]

Thanks a mill for response.

I am guessing this is the relay but not having much luck in figuring out how to remove. There is a screw into a metal place at front that I can access but I can also feel one in behind with no way to access. Also struggling to disconnect the wiring connection at bottom of relay.


View attachment 484582

Steady here folks, the photo resembles an inertia switch. If it is the inertia switch then it will have a big button or cap that is used to reset if triggered. A typical mounting place for the glow plug relay was over the battery, on the RHS inner wing. See attached photo titled "starter relay", of my 1990 Talbot Express, where large blue object is glow plug relay, and also compare OP's photo with my photo of the inertia switch on my 2006 2.8jtd.

@donaldinho if you disconnect the inertia switch, you will not be able to start the engine, this also applies if you disturb the switch too much.

 

[Communicator]

Thanks a mill for response.

I am guessing this is the relay but not having much luck in figuring out how to remove. There is a screw into a metal place at front that I can access but I can also feel one in behind with no way to access. Also struggling to disconnect the wiring connection at bottom of relay.


View attachment 484582

When you find the correct component, please note that most automotive connectors have a mechanical latch, that has to be held in when separating the connector.

 

[bugsymike]

Steady here folks, the photo resembles an inertia switch. If it is the inertia switch then it will have a big button or cap that is used to reset if triggered. A typical mounting place for the glow plug relay was over the battery, on the RHS inner wing. See attached photo titled "starter relay", of my 1990 Talbot Express, where large blue object is glow plug relay, and also compare OP's photo with my photo of the inertia switch on my 2006 2.8jtd.

@donaldinho if you disconnect the inertia switch, you will not be able to start the engine, this also applies if you disturb the switch too much.

Good spotting , I could only see a bit of the plug from OPs photo and like you most of the heater plug relays are rectangular.

 

[Communicator]

Good spotting , I could only see a bit of the plug from OPs photo and like you most of the heater plug relays are rectangular.

You will have met many more than me.

 

[bugsymike]

You will have met many more than me.

But my memory is going faster, although somewhere in my garage I have one of those rectangular ones, pretty ancient though and may have been for a Peugeot 504 diesel pick up as I had two of them.

 

[bugsymike]

But my memory is going faster, although somewhere in my garage I have one of those rectangular ones, pretty ancient though and may have been for a Peugeot 504 diesel pick up as I had two of them.

I often used to boast I had everything except money in my garage, but could never find it. Funny enough it even has Fiat written on it.

 

[donaldinho]

Steady here folks, the photo resembles an inertia switch. If it is the inertia switch then it will have a big button or cap that is used to reset if triggered. A typical mounting place for the glow plug relay was over the battery, on the RHS inner wing. See attached photo titled "starter relay", of my 1990 Talbot Express, where large blue object is glow plug relay, and also compare OP's photo with my photo of the inertia switch on my 2006 2.8jtd.

@donaldinho if you disconnect the inertia switch, you will not be able to start the engine, this also applies if you disturb the switch too much.

Thanks a million, I thought the clicking was coming from that switch but will have another root around this evening. Appreciate your help here.

 

[donaldinho]

I've had another go and identifying the relay . . it's hard to pinpoint exaclty where the clicking sound is coming form, although it is very loud!

The pic below shows the area above the battery, and below are 2 close-ups of that area.

 

[bugsymike]

It does look like the heater plug relay but although similar to mine at #10, but yours has a plastic screw to undo to release some of the connectors.

 

[Communicator]

I've had another go and identifying the relay . . it's hard to pinpoint exaclty where the clicking sound is coming form, although it is very loud!

The pic below shows the area above the battery, and below are 2 close-ups of that area.

View attachment 484702

Yes as @bugsymike has said it does resemble a glow plug relay. I am thinking that the cylindrical reference in post #1 refers to the round connector for the control and indication wires. On older relays the supply and glow plug connections were via two studs, perhaps 5 or 6mm diameter.

One of the studs may be connected directly to the battery positive. Standard safety precaution is to disconnect the battery negative before starting work.