You definitely DO NOT HAVE TO LOOSEN THE INLET MANIFOLD to replace the glow plugs on the Renault Espace (transverse Laguna engines eg. 2.2DT) Although the replacement procedure in the Renault manual states that you must undo the inlet manifold to gain proper access to the glow plugs for removal, it is not necessary to do this.
The glow plugs are definitely a little bit awkward to gain access to, but with a steady hand, a little bit of patience, and the right tools. The glow plugs can be replaced without having to remove anything other than the glow plugs and their electrical connectors.
The Tools required are as follows:
DIESEL GLOW PLUG SOCKET SET.
There are several makes available but I used a Sealey set model no. SX0402, the 10mm socket with rubber gripper insert. They definitely work in the very tightly confined space that you have to reach the glow plug.
3/8 DRIVE SOCKET SET
The minimum components required are 3/8 Sliding T-Bar, 3/8 Ratchet, 3/8 15" Breaker Bar, 150mm Extension Bar, and a 75mm Extension Bar.
1/4 DRIVE SOCKET SET
The minimum components required are 1/4 Sliding T-Bar, 1/4 Ratchet, 1/4 Universal Joint, 10mm Deep Reach Socket. It's either a 7mm or 8mm socket that's required to remove the electrical connection nut on the glow plug
SMALL MAGNET
The small pocket telescopic type that are used for retrieval of nuts or bolts when lost in awkward places.
COMPRESSED AIR LINE or BICYCLE PUMP
Blowing the area around the glow plug with compressed air before removal ensures that any debris or foreign bodies are cleared from the glow plug recess before removal. A bicycle pump with an open rubber adaptor tube connected is a good alternative. It really is very important to make sure the area directly around the glow plug is clear before removal.
EXTRA LONG NOSE PLIERS
These are used for removing the glow plug once it's fully loosened, and also to place the new glow plug into location.
WIRE COATHANGER
Straighten the coathanger wire out, and cut a couple of 300mm lengths. Bend a 6mm hook on the end of one wire and a small 8mm 'S' at right angles to the wire. The 6mm hook is useful for unhooking the power wire from the glow plug after the 7mm/8mm nut is removed. The 'S' is useful for replacing power wire onto the new glow plug.
BLUE TAC
This is helpful when placing the new electrical connection nut onto the newly fitted glowplug.
A DECENT BRIGHT LIGHT
I used a very small flexible low heat spotlight that I fed under the inlet manifold to illuminate the area around glow plug to be removed.
REMOVAL PROCEDURE IS AS FOLLOWS:
1. For safety: undo the positive lead to the battery and place it safely away from the positive battery terminal (make sure you know your radio security code before you do this, you'll need it on reconnection)
2. If you intend to replace all of the glowplugs. Start with the one on the far right nearest to the air filter, and work from right to left, it takes the tension off the power lead cable making it easier for access.
3. Get a decent light to the area around the glow plug to be removed.
4.Clean around the glowplug to be removed with compressed air, and make sure there is no chance of anything entering the glow plug hole when the plug is removed.
5. Using a 1/4 sliding T-bar, extention bar, universal joint, with either a 7mm/8mm socket depending on the size of the nut. Remove the electrical connection nut. Once undone retrieve the nut using the magnet.
6. Lift the power lead off the glow plug terminal using the coathanger wire hook. Use wire, string, or zip clips to keep the power lead out the way, so that you have clear access when placing the 10mm glow plug socket over the glow plug.
7. Using the 3/8 sliding T-bar, 75mm extention bar, and 10mm glow plug socket. Place the 10mm glow plug socket over the plug. One you've ensured the socket is securely fitted over the glow plug, make sure that the 75mm extention bar is pushed against the 'V' of the inlet manifold (this is because with the bar in the most upright position you can apply maximum force to undo a very tight glow plug) If the glow plug seems stuck fast, use the 15" breaker bar instead of the T-bar, but keep the extention bar as upright as possible while applying force. Turn the 15" breaker bar very slowly and a little at a time. Once your at the point where the glow plug turns easily, it may be easier to use the 1/4 T-bar, extention bar, universal joint, and 10mm deep reach socket to do the last bit (There isn't quite enough clearance to totally remove the glow plug with the 3/8 10mm socket).
8. Once the glow plug is totally undone, remove the 1/4 10mm socket from the glow plug very carefully. You may be lucky and the glow plug comes out attached to the socket. If it doesn't come out with the socket, grip the threaded terminal post on top of the glow plug with the extra long nose pliers and lift up vertically and remove it.
9. Have the new glow plug ready with the terminal nut removed, and sit it in the hole using the extra long nose pliers.
10. Gently place the 1/4 T-bar, extention bar, universal joint, and 10mm deep reach socket over the new glow plug, making sure that the glow plug is perfectly upright. Carefully and gently turn the glow plug clockwise until it starts to take up the thread (BE EXTREMELY CAREFUL NOT TO CROSS THREAD THE GLOW PLUG IN THE HOLE). Tighten the glow plug up firmly until you feel it stop. Use the 3/8 sliding T-bar, 75mm extention bar, and 10mm glow plug socket for the final check that the glow plug is securely tightened. Don't use excessive force but you should feel the glow plug is now fully home and tightened.
10. Using the wire 'hook' and 's' place the power wire onto the glowplug terminal.
11. Place a small amount of 'blue tac' around the terminal nut and push it into the 7mm or 8mm socket. Then using the 1/4 T-bar, extension bar, and universal joint place the nut gently on the glow plug terminal, but be very careful not to cross thread the nut on the terminal.
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Repeat the above procedure for each glow plug. If you are doing all four of them, it's easier to undo all the power wires to the glow plugs first and then when the new glow plugs are fitted, reconnect them all loosely first from right to left. WARNING! MAKE SURE EACH CONNECTOR LEAD IS TIGHTENED IN A POSITION THAT THEY ARE NOT MAKING ANY ELECTRICAL CONTACT WITH THE CYLINDER HEAD.
I've done my best to describe how it's done. It's a very fiddly job and it will probably take you an hour or two. Personally I think it's a lot easier than undoing the inlet manifold.
GOOD LUCK!
REX
REX (RSWPOST@AOL.COM), March 2008
