As explained in my last post, the glow plug controller replacement did not cure my number 6 error code so it was on to glow plug replacement. It makes no sense to replace them one at a time so I bought a full set of six OE Beru plugs from Euro Car Parts for £67.39 and set about replacement.

The intake manifold had to come off again which made me wish I had done this job when I removed my swirl flaps but you live and learn. At least I knew how it all came apart this time!

Once I had access it was on to old plug removal and this was a very nervy affair! These things tend to seize up a bit and also tend to snap off very easily which often requires cylinder head removal so extreme care is needed. First I started with a warm engine, letting it cool just enough to not burn myself before starting work. Then I soaked the plugs in proper release fluid Plusgas (not WD-40). I then got a torque wrench set to initially 20NM and tried each of the plugs to see if any were removable. Nope!

I then waited 10 mins for the Plusgas to penetrate and tried again. Nope! Then I increased torque to 25NM and got two plugs out. It’s a good idea to wind them back and forth a bit even once they start to move since they tend to get sticky as you remove them and make a horrible screeching sound. Patience patience patience!

I waited a bit longer after applying more Plusgas and got another two out at 25NM before increasing to 30NM and trying a few times before finally getting the last two out. Phew!

After that it was a relatively simple case of applying a thin smear of anti-seize grease to each new plug and installing them and torquing them up. Then remove all the blue paper from the intake tracts before replacing the manifold. The fault code was cleared and never returned! Result!