P38 '97 2.5 DSE manual glow plug change

So, I'm changing the glow plugs.
Its an aluminium inlet manifold, and that has to come off to make doing the plugs easier, so I got new gaskets. Seeing as I'm in this vicinity, I've also been advised to take the opportunity to change the leak-off hoses, and I got a length of fuel hose to do this, using the old ones as templates. All good so far, got everything ready, just wondered if there is anything that I should watch out for, any common mistakes or problems that happen that I should avoid, any hints or tips about making things go smoothly?
Already been advised to use rags to block off the inlet chambers to avoid dropping stuff into the pots (lol, poor guy who mentioned that managed to drop 3... yes 3, of the 8mm nuts that are on the top of the glow plugs down there!!!). Over to you guys.

Copperslip the threads of the new heater plugs when you refit them,make sure you use good quality ones. I used heat shrink on the ends of the new leak off pipes. Get the best pipe you can ,I got some Bosch on the bay

WayneRR4x4 said:

any common mistakes or problems

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As you said, be careful with dropping bits into the inlet after the manifold is off, other than that the only other big cock up is from bits of a buggered plug dropping down into the precup or shearing a plug off into the head if they've never been changed or been dead for a long while and seized in. Worm them in and out if they're very stiff (once cracked off), in order to loosen any stuck carbon into small chunks (protects the heads thread and old plug tip from being damaged - and don't get a breaker bar on them if you cant get the threads to crack off, heat em up and try again with a small bar only - I've had good luck with a small 30nm impact driver on stuck plugs in the past as an extra thing to try if you need inspiration.

Make sure you put some copper grease / ceramic grease on the new plug bodies and threads as well, to make next change nice n' easy

Also have a look at the tips of the old plugs (and remember which cylinder had which plug), it'll reveal all sorts of handy info, things such as melted / distorted tips being bad signs!

WD40 is about the only help I've got for stuck plugs lol. Copper grease is a good call, I'll pick some up before I start.

WayneRR4x4 said:

WD40 is about the only help I've got for stuck plugs lol. Copper grease is a good call, I'll pick some up before I start.

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WD40 is not penetrating fluid.

Aye WD-40 isnt much help for such things, home brewed half and half ATF + whatever thinners you have in the shed is a preferable penetrant (acetone / ATF mix being most ideal for example), if you can't get any of the decent penetrant sprays from a local motor-factors that is.

Goc3k said:

Aye WD-40 isnt much help for such things, home brewed half and half ATF + whatever thinners you have in the shed is a preferable penetrant (acetone / ATF mix being most ideal for example), if you can't get any of the decent penetrant sprays from a local motor-factors that is.

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Plusgas.

When refitting the intake , take care not to crush the 4th injector wire

Make sure you have a telescopic magnet handy! There's a clip on the last manifold nut right at the back where you cannot see it so make sure that goes back on.

Try not to disturb the wire on number 4 injector,they are easy upset with age and going brittle ...And when you take off the leakoff pipes diesel runs back to tank ,and can take a bit o cranking so a good battery helps

dubbleRR said:

Try not to disturb the wire on number 4 injector,they are easy upset with age and going brittle ...And when you take off the leakoff pipes diesel runs back to tank ,and can take a bit o cranking so a good battery helps

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This happened to me. Moved the wire as it was rubbing and ended up needing a new injector. £250 OUCH.

I've changed the glow plugs twice on mine, first time without a problem, and I am a disaster area when it comes to diy maintenance.

EntropyUK said:

This happened to me. Moved the wire as it was rubbing and ended up needing a new injector. £250

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Plusgas - swear by the stuff.

Use good quality plugs, I had a cheap set fail after a few years, try and do it while the engine is still warm, if you put a bit of card/paper in the socket, then jam the nut in, it makes removal/refitting easier as you can use an extension to get in the fiddly places. I used all 1/4 drive tools when doing my plugs last. Oh, there is a vaccum hose that goes around the engine. Makes sure you put the rubber grommet in the right place before refitting the inlet manifold, it doesn't fit otherwise... mine didn't anyway.