Express, Savana, G1500, G2500, G3500, 1998-2005

Glow Plugs

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Removal & Installation



  1. Remove or disconnect the following:
    NOTE
    On vehicles with Federal emissions systems, there is a buss bar connecting the glow plugs on each bank of the engine.



    Negative battery cables
     
    Front tire
     
    Inner splash shield from the fender well
     
    Air cleaner outlet duct
     
    Electrical nuts from the glow plug(s)
     
    Harness from the glow plug(s)
     



    Glow plug(s)
     

  2.  

To install:

  1. Install or connect the following:

    Glow plug and tighten to 13 ft. lbs. (18 Nm)
     
    Buss bar and wiring
     
    Glow plug electrical nut and tighten to 13 inch lbs. (1.5 Nm)
     
    Air cleaner outlet duct
     
    Splash shield to the fender well
     
    Negative battery cables
     

  2.  

Left Side
  1. Disconnect both battery cables.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. On the left side, remove the left front tire.
  6.  
  7. Remove the splash shield from the left front wheel well.
  8.  
  9. Remove the lead wires from the glow plugs in cylinders 1 and 3.
  10.  
  11. Remove the glow plugs from cylinders 1 and 3.
  12.  
  13. Remove the engine cover.
  14.  
  15. From the inside of the vehicle, remove the lead wires from the glow plugs in cylinders  5 and 7.
  16.  
  17. Remove the glow plugs from cylinders 5 and 7.
  18.  
  19. On the right side, remove the right front tire.
  20.  
  21. Remove the splash shield from the right front wheel well.
  22.  
  23. Remove the lead wires from the glow plug in cylinder 2.
  24.  
  25. Remove the lead wires for the glow plugs in cylinders 4 and 6 at the harness connectors.
  26.  
  27. Remove the glow plugs from cylinders 2, 4, and 6.
  28.  
  29. Disconnect the lead wire at the glow plug from cylinder 8 from inside of the vehicle.
  30.  
  31. Remove the glow plug from cylinder 8.
  32.  

To install:

  1. On the right side, install the glow plug into cylinder 8 from inside of the vehicle and tighten to 13 ft. lbs. (17 Nm).
  2.  
  3. Connect the lead wire to the cylinder 8 glow plug.
  4.  
  5. Install the glow plugs into cylinders 2, 4, and 6 by reaching through the right front wheel well and tighten to 13 ft. lbs. (17 Nm).
  6.  
  7. Install the lead wire to glow plug 6.
  8.  
  9. Connect the wires for the glow plugs in cylinders 4 and 6 to the connectors at the wire harness.
  10.  
  11. Install the lead wire for the cylinder 2 glow plug.
  12.  
  13. Install the splash shield in the right front wheel well.
  14.  
  15. Inspect the wire routing, ensuring that the lead wires are not rubbing against the exhaust manifold or any part that may harm the wire insulation.
  16.  
  17. Install the right front tire.
  18.  
  19. On the left side, install the glow plugs into cylinders 1 and 3 by reaching through the left front wheel well and tighten to 13 ft. lbs. (17 Nm).
  20.  
  21. Install the lead wires for cylinder 1 and 3.
  22.  
  23. Install the splash shield in the left front wheel well.
  24.  
  25. Inspect the wire routing, ensuring that the lead wires are not rubbing against the exhaust manifold or any part that may harm the wire insulation.
  26.  
  27. Install the left front tire.
  28.  
  29. Install the glow plugs into cylinders 5 and 7 from inside of the vehicle and tighten to 13 ft. lbs. (17 Nm).
  30.  
  31. Connect the lead wires to the glow plugs.
  32.  
  33. Connect the negative battery cables.
  34.  
  35. Ensure that the PCM electrical harness is properly routed to avoid contact with the engine cover during installation.
  36.  
  37. Install the engine cover.
  38.  

Right Side
  1. Remove or disconnect the following:

    Negative battery cables
     
    Glow plug lead wires
     
    Plugs
     
    Right front tire
     
    Inner splash shield from the fender well
     
    Lead wire from the plug at the No. 2 cylinder and the lead wires from plugs in the Nos. 4 and 6 cylinders at the harness connectors
     
    Heat shroud for the plug in the No. 4 and 6 cylinder. Slide the shrouds back just far enough to allow access so you can unplug the wires.
     
    Glow plugs in cylinders No. 2, 4 and 6.
     

  2.  
  3. Reach up under the vehicle and disconnect the lead wire at No. 8. Remove the glow plug.
    NOTE
    You may find that removing the exhaust pipe down might make this a bit easier when working on Nos. 6 and 8.

  4.  

To install:

  1. Install or connect the following:

    Glow plugs and tighten to 16 ft. lbs. (22 Nm)
     
    Heat shrouds and electrical connection
     
    Exhaust pipe, if removed
     
    Splash shields, if removed
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the heat shrouds and glow plug wiring-6.5L diesel engine

     

  2.  

 
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