You will need a 3/8 drive ratchet and 6 inch extension bar, 10mm socket, a 8mm socket, a 12mm long reach socket, a universal joint, a set of Allen keys, a new inter-cooler to manifold gasket, thread lock liquid (Locktite) and a flat blade screwdriver. The inter-cooler lies across the top of the engine and has to be removed for access. Make sure the engine is cold. Undo the two 10mm screws (front) and 3 Allen screws (rear) from the inter-cooler. loosen the large jubilee clip and pull the inter-cooler off the large rubber hose. Flip the inter-cooler forward so it lies on top of the radiator filler. There is no need to remove the thin pipe. The glow plugs sit in a line behind the fuel pump and dipstick holder. They are wired together and there is a feed wire. Using the 8mm socket, extension and universal as necessary remove the nuts and wires from the glow plugs. Note glow plug 3rd from the left (facing) has the wire that connects the four together and the feed wire connected to it. With the 12mm long reach socket, extension and universal as necessary remove and replace the glow plugs one by one. Refit the wiring and, using thread-lock on the Allen screws, replace the inter-cooler, replacing the gasket as you go. Note: the longer Allen screw goes nearest the battery. Ensure the jubilee clip is tight. Clear all tools away. Start the car.
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May 2009
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