Ciroen Relay 2.2 HDi glow plug replacement

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fordyamr1
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Ciroen Relay 2.2 HDi glow plug replacement

Post by fordyamr1 »

Having had starting problems with my 2010 138000 miles Relay 2.2 HDi last winter, I decided to change the glow plugs before this one.
To do this, I completely removed the front grille and grille surround which contain mainly large headed torque screws (I used a torque screw penknife type tool bought from Aldi for about £5).
I then removed the slam panel which has 6 x 10mm (hexagon head) bolts, there are 2 x star headed (Philips) screws that keep the air intake tube fastened to the panel to be removed on the back side also.
Next was to remove the 2 screws (7mm hex) that holds the EGR valve pipe (silver pipe) from it's housing. Just to the left of the silver pipe are a further 2 x 8mm bolts that hold the intake pipe for the EGR that allow you to move the inlet manifold later.
The inlet manifold is held in place by 9 x 10mm hex head bolts. All of these bolt were the type that stay within their holes so they don't drop out and get lost
Once you have these unscrewed you can then lift the manifold up (with a little bit of maneovering) to get to the glow plugs. You also need to unscrew the 2 x 7m hex head screws that hold the dipstick tube in place so that you can turn the holding bracket out of the way.
With the manifold out of the way you can now see the 4 x glow plugs and their electrical harness. Remove the small nuts to loosen off the harness, the plugs can now be removed with a normal 10mm hex (half inch drive) socket. Remove them and replace with new then reverse the whole procedure.
It's a bit of a faff on but it's not a hard job that can be taken on by most home mechanics (with the right tools) in about 4 hours. I held the water pipe out of the way with a bungee. There's no need to remove the radiator, you can see there is plenty of room to work if you look at the images attached. There are NO gaskets to replace the manifold has rubber seals, mine were in good condition.

Looking at the images - the top set of holes is the inlet manifold lifted out of the way. The bottom set of holes are the manifolds corresponding holes in the cylinder head (these fit together when bolted up). The dipstick is yellow. Between the 2 sets of holes and near the bottom of the yellow on the dipstick are the 4 x glow plugs across the engine, (small bright silver nuts - these were the new ones in situ).
Now looking forward to a good starting winter engine.
Attachments
4 glow plug nuts in line with the bottom of the yellow on the dipstick
4 glow plug nuts in line with the bottom of the yellow on the dipstick
You can just see the ribbed glow plug harness between the 2 sets of holes
You can just see the ribbed glow plug harness between the 2 sets of holes
Radiator still in situ
Radiator still in situ
Better picture of the 4 glow plugs
Better picture of the 4 glow plugs
Top view of everything
Top view of everything
View of what needs to be removed to get at everything
View of what needs to be removed to get at everything
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Re: Ciroen Relay 2.2 HDi glow plug replacement

Post by GiveMeABreak »

Hi and welcome - that's a very informative first post that I'm sure will be apppreciated.!
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Re: Ciroen Relay 2.2 HDi glow plug replacement

Post by Hell Razor5543 »

Hi, :welc: to the forum, and if you continue with threads like this you will be highly followed! :D
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Re: Ciroen Relay 2.2 HDi glow plug replacement

Post by Michel »

Best first post ever!
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Re: Ciroen Relay 2.2 HDi glow plug replacement

Post by white exec »

Terrific post, with lots of helpful detail.
What a grizzly amount of work, though, just to replace four GPs!
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Re: Ciroen Relay 2.2 HDi glow plug replacement

Post by gordie303 »

Just what I was looking for, Thank you so much
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