How do you change the glow plugs on a Peugeot Expert?

Answer 1

1,9 2002 plate models have a shed load of plastic and pipes in the way.

I have to do this this week end as I gave up last week.

It turns out that there are Two, possibly 3 Allen screws at the back of the intake manifold! these are at the top. I have found two between the end intake tubes and they appear to be 5mm standard Allen hex bolts.

I am reliably told that the assembly is very tight to remove. There is also a hex bolt which holds the metal pipe to the cylinder head on the drivers side, easily removed.

I don't know how much movement or access this gives but its got to be better than with the bolts in. What a crap design using so many types of screw thread.

Hi, my sentiments exactly, what a load of cobblers, the designer must be 6 years old !!

There are in fact as you say two, 5mm hex bolts in between the end air

intake pipes on a 45% angle , There are also two 7mm hex bolts holding the front end down to the cylinder head, one to the left of the oil filler cap, and one in the same position on the right hand side of head, they are about 75mm down a half tube, so with cylinder head bolts about half-way down and about 75mm space to bulk-head above I wish you luck with it, I spent three hours on those four bolts alone!! With the four bolts out release the flange clip on the steel flexi pipe on the left, Then disconnect the rubber breather pipe on the right, Lift the front end of intake and disconnect two wires from the glow plugs on the same terminal on the right hand side, Next disconnect electrical terminal and small pipe below the front air throttle intake, Now with a strong pull forward you can release the unit, You cannot remove it over the top of the rocker box because there is not enough clearance on the bulk-head, unless you disconnect gearbox end mounting and lower transmission, Suffice to say I didn't want that option! However I managed to push the intake over to right and prop it up to give me enough access to release number three and four glow plugs, Then I pushed and prop it up on the left to access one and two glow plugs, although extremely limited space I did manage it.

On re-assembly make sure the rubber seals on the intake manifold pipes are in place before pushing back home, you can only do this by feeling around the back because you can't see them.

It actually took me 10 hours from start to finish, but after 3 hours of frustration

trying to remove hex bolts, it's all behind me thank goodness, and she starts instantly now.

Good luck, Stuart !