Chapter 5 Part Cc: Preheating system - diesel models Contents Gb pigs removal, inspection and rfiting 2. Preheating system components - removal and refting ......-.+. 8 Preneating system - general description and testing 4 Degrees of difficulty Easy, suitable for ‘novice with ite ‘experience Specifications Torque wrench settings Gow plugs: 1.7 litre models, 20 litre models 20 10: 5 1. Preheating system - description and testing Description 4 Each oylinder of the engine is fitted with a heater plug (commonly called a glow plug) screwed into it. The plugs are electrically: operated before and during start-up when the engine is cold. Electrical feed to the glow plugs Is controlled via a relay and the preheating system control unit (1.7 litre models) forthe injection system ECU (2.0 litre models). 2A warning light in the instrument panel tells the driver that preheating Is taking place. ‘When the light goes out, the engine is ready to be started. The voltage supply to the glow plugs continues for several seconds after the Hight goes out. Ino attempt is made to start, the timer then cuts off the supply, in order to avoid draining the battery and overheating the dow plugs. 3 The glow plugs also provide a ‘post-heating’ function, whereby the glow plugs remain ‘itched on for a period after the engine has started, The length of time ‘post-heating’ takes place for is also determined by the control unit but it can be anything up to 6 minutes, depending on engine temperature. 4 On 1.7 Itre models the fue iter is also fitted with a heating element to prevent the fuel ‘waxing’ in extreme conditions and to improve combustion. The heating element is fitted between the filter and its housing and is controlled by the preheating system control unit via the temperature switch on the filter housing. The heating element is switched on if the temperature of the fuel passing through the fiter is less than 5°C (41°F) and switches ‘off when the fuel temperature reaches 16°C (r"A. Testing 5 If the system malfunctions, testing is tltimately by substitution of known good tnits, but some preliminary checks may be made as follows. 6 Connect a voltmeter or 12-volt test lamp between the glow plug supply cable and earth (engine or vehicle metal). Make sure that the live connection is kept clear of the engine and bodywork 7 Have an assistant switch on the ignition, ‘and check that voltage is applied to the glow pplugs. Note the time for which the warning light is lit, and the total time for which voltage {is applied before the system cuts out. Switch ‘off the ignition. 8 At an under-bonnet temperature of 20°C (68°F), typical times noted should be approximately 3 seconds for warning light ‘operation. Warning light time will increase with lower temperatures and decrease with higher temperatures. 9 If there Is no supply at all, the control unit, relay or associated wiring is at fault. 10 To locate a defective glow plug, slacken land remove the nuts and washers (where fitted) then disconnect the main supply leads) and the electrical supply rail from the plugs. On later models simply pull off the wiring connector from each plug 411 Use a continuity tester, or a 12-volt test lamp connected to the battery positive terminal, to check for continuity between each {glow plug terminal and earth. The resistance fof a glow plug in good condition is very low {loss than 1 ohm), s0 i the test lamp does not light or the continuity tester shows a high resistance, the glow plug is certainly defective, 42 If an ammeter is available, the current draw of each glow plug can be checked. After an initial surge of 15 to 20 amps, each plug should draw 12 amps. Any plug which draws much more or less than this Is probably defective 13 As a final check, the glow plugs can be removed and inspected as described in the following Section. 2 Glow plugs - removal, inspection and refitting Caution: If the preheating system has just been energised, or if the engine has been ‘unning, the glow plugs will be very hot. Removal 1.7 litre models 4 Disconnect the battery negative lead. To improve access, disconnect the breather hose {rom the rear of the cylinder head cover. 2 Slacken the nut securing the electrical supply rail to each glow plug then slide the rail to the rear to disengage it from the glow plugs.5Ce2 Preheating system - diesel models 2.5 On 2.0 litre engines, unscrew the retaining nut from each glow plug . 3 Unscrew the glow plug(s) and remove from the cylinder head. 2.0 litre models 4 Disconnect the battery negative lead. If necessary, to improve access, remove the ‘metal pipe linking the turbocharger to the ‘manifold/intercooler duct (see Chapter 4). 5 On early models undo the retaining nuts ‘and washers from the top of each glow plug then disconnect the wiring connectors and lft off the electrical connecting rails (see illustrations). On later models simply disconnect the connector from the top of the each glow plug. 66 Unscrew the glow plug(s) and remove them from the cylinder head. Inspection 7 Inspect each glow plug for physical damage. Burnt or eroded glow plug tips can be caused by a bad injector spray pattern Have the injectors checked if this sort of ‘damage is found. 8 If the glow plugs are in good physical Ccondition, check them electrically using a 12 volt test lamp or continuity tester as described in the previous Section. 9 The glow plugs can be energised by ‘applying 12 volts to them to verify that they hheat up evenly and in the required time. ‘Observe the following precautions. '@) Support the glow plug by clamping it carefully in a vice or self-locking pliers. Remember it wil become red-hot. »b) Make sure that the power supply or test ead incorporates a fuse or overioad trip to protect against damage from a short- circu. ©) After testing, allow the glow plug to cool for several minutes before attempting to handle it 10 A glow plug in good condition will start to glow red at the tip after drawing current for 5 Seconds or so. Any plug which takes much. longer to start glowing, or which starts glowing in the middle instead of at the tip, is. detective. Refitting 4.7 litre models 11. Carefully refit the plug(s) and tighten to the specified torque. Do not overtighten, as this can damage the glow plug element. 12 Ease the electrical supply rail into position, ensuring itis correctly engaged with each of the four glow plugs, and securely tighten the glow plug nuts. 13 Reconnect the breather hose then ‘connect the battery and check the operation of the glow plugs. 2.0 litre models 14 Carefully refit the plug(s) and tighten to the specified torque. Do not overtighten, as this can damage the glow plug element. 415 On early models, refit the supply rails) to the glow plugs, reconnect the wiring con- rectors) then refit the washers and retaining ruts and tighten securely. On later models reconnect the connectors securely to the plugs. 16 Refit the metal pipe (where removed) to the turbocharger/duct (see Chapter 4) then reconnect the battery and check the operation of the glow plugs. 3. Preheating system components - removal and refitting 1.7 litre models Preheating system control unit 41 The unit is located on the left-hand side of the engine compartment where it is mounted ‘onto the rear of the battery box. 2 Disconnect the battery negative lead. 3 Unscrew the retaining nut securing the unit to the battery box. 4 Disconnect the wiring connector from the base of the unit then unscrew the two retaining nuts and free the main feed and ‘supply wires from the unit. Remove the unt from the engine compartment. 5 Refiting is a reversal of removal, ensuring that the wiring connectors are correctly connected, Coolant temperature sensor 6 The coolant temperature switch is screwed into the thermostat housing. Refer to Chapter 3 for removal and refiting details Fuel filter heating element 7 Remove the fuel filter as described in ‘Chapter 1. Ifthe fiter is damaged on removal (which is likely), a new one should be used on refitting. 8 Disconnect the battery negative terminal then disconnect the wiring connector from the heating element. ‘9 Unscrew the centre bolt and remove the heating element from the filter housing, Recover the sealing ring and discard, a new ‘one should be used on refiting. 10 Fit a new sealing ring the heating element recess then refit the element to the fiter housing and securely tighten the centre bot. 41 Reconnect the battery then fit the fuel filter as described in Chapter 1. Fuel filter heating element temperature switch 42 Disconnect the battery negative termina then disconnect the wiring connector from the ‘temperature switch which is screwed into the {ual fiter housing, 13 Position a wad of rag beneath the fier housing to catch any spilt fuel then unscrew the switch and remove it from the housing, Plug the housing aperture to prevent the enty, of dirt and minimise fuel loss. Remove the sealing ring from the switch and renew them, 14 Fit new sealing rings to the switch recesses then refit the switch to the fet housing and tighten securely. Reconnect the wiring connector to the switch then reconneet the battery, Relays and fuses 15 The glow plug and fuel heating element relays and fuses are located in the box in the tengine compartment. Refer to Chapter 12 ft further details. 2.0 litre models 16 The operation of the preheating systems controlled by the injection system ECU andits sensors, Refer to Chapter 4 for further information.