Glow plug #4 - how easy? and P/N?

dirtmover · **Posted:** Wed Sep 30, 2009 7:48 am

#4 has just gone. Has anyone changed it and got any tips? How easy?

I see #1 is accessible and the dealer already did #3 under warranty - took about 3 hours labour!

Also, can anyone confirm from first hand experience if the Bosch 80041 is the same at the Mopar part. Dealers here want $72 each :cry:

and I can buy the Bosch part for about half this!

The references I have found so far have inconsistencies suggesting our engine is Detroit Diesel and the Bosch plugs are Inconel 601 which is a nickel-chromium alloy - not ceramic as indicated on the yellow sticker.

The Bosch distributor in town says that the 80041 doesn't appear in his catalogue and the Bosch website does not list this plug.

This seems to be the most authoritative indication http://www.o-f-i.com/index.php?pid=56 - since they specialise in diesels - that the Bosch part is equivalent to the OEM# 5142577AA.

This is on a 2006.

Joe Romas · **Posted:** Wed Sep 30, 2009 10:50 am

When our engines were made VM was owned by Detroit Diesel at 48% and Pensky group @ 52%. That may explain the Detroit part. Then there's a sticker on front of the engine saying we have 7 volt Ceramic resisters. That would lead me to beleave VM originally used metal glow plugs in an earlier engine.

As a side note VW is recalling their cars with ceraic glow plugs and is putting in metal ones.

Not much help I know :wink:

CATCRD · **Posted:** Wed Sep 30, 2009 5:45 pm

dirtmover wrote:

#4 has just gone. Has anyone changed it and got any tips? How easy?

I see #1 is accessible and the dealer already did #3 under warranty - took about 3 hours labour!

Also, can anyone confirm from first hand experience if the Bosch 80041 is the same at the Mopar part. Dealers here want $72 each :cry:

and I can buy the Bosch part for about half this!

The references I have found so far have inconsistencies suggesting our engine is Detroit Diesel and the Bosch plugs are Inconel 601 which is a nickel-chromium alloy - not ceramic as indicated on the yellow sticker.

The Bosch distributor in town says that the 80041 doesn't appear in his catalogue and the Bosch website does not list this plug.

This seems to be the most authoritative indication http://www.o-f-i.com/index.php?pid=56 - since they specialise in diesels - that the Bosch part is equivalent to the OEM# 5142577AA.

This is on a 2006.

I can confirm first hand that 80041 is the right Bosch part. That's what I ordered from Rock auto when mine blew and it's working fine.

dirtmover · **Posted:** Wed Sep 30, 2009 5:53 pm

Thanks CATCRD. I just cleared them out of their last 4. Funny thing is they dont even list them in the CRD application.

dirtmover · **Posted:** Sat Oct 03, 2009 8:09 am

So I got round to checking the FSM and find the cautions interesting, especially the last one

CAUTION:
- Never bend, bump or knock the ceramic glow
plugs.
- Ceramic glow plugs must not be handled loose
in a container. Store, handle, and transport them
only in original boxes.
- If there is any doubt about the proper condition
of a glow plug, do not use it anymore.
- Do not clean the glow plugs with abrasive or
aggressive media.
- Avoid dipping the glow plug into fluids.
- Read Diagnostic Trouble Codes (DTCs). If a
glow plug problem is indicated, do not start the engine.
CAUTION: Disregarding these instructions may cause severe engine damage.

Given this last warning does enyone else find it strange that:
- a glowplug related DTC's does not cause a flashing CEL
- a dealer would send a customer away with a glowplug related DTC for a few days while they order a replacement
- the CEL doesn't even get lit until after the engine is started (a bit too late by then)

ATXKJ · **Posted:** Sat Oct 03, 2009 4:57 pm

If the glow plug pieces are large enough to cause damage
then it will be done on the first engine revolution
and since the glow plug will die as you are starting the engine, the damage will be done by the time the light comes on.
the warning is an attempt to avoid legal responsibility.

overwhelmingly the glow plugs break in small enough pieces to blow out the exhaust -
but Darby's didn't - it killed the engine, and MrMopar had one die.

if you break one while you're working on it - be prepared to pull the head
(or at least an injector to get a borescope down it - sounds like no one makes one small enough for the glow plug hole)

nescosmo · **Joined:** Sat Jul 14, 2007 11:17 pm **Posts:** 202

ATXKJ wrote:

If the glow plug pieces are large enough to cause damage
then it will be done on the first engine revolution
and since the glow plug will die as you are starting the engine, the damage will be done by the time the light comes on.
the warning is an attempt to avoid legal responsibility.

overwhelmingly the glow plugs break in small enough pieces to blow out the exhaust -
but Darby's didn't - it killed the engine, and MrMopar had one die.

if you break one while you're working on it - be prepared to pull the head
(or at least an injector to get a borescope down it - sounds like no one makes one small enough for the glow plug hole)

What is a borescope and if you break an small piece, can you use a vaccum on the hole to see if you can pull the piece out.

ATXKJ · **Posted:** Sun Oct 04, 2009 8:20 am

nescosmo wrote:

What is a borescope

We hope Google is our friend because they have all knowledge in the world (or at least the web)

Wiki
http://en.wikipedia.org/wiki/Borescope

Tool Desk
http://www.tooldesk.com/products/default.aspx+sid+209

I would doubt that a piece big enough to cause damage would come out through the glow plug hole - if there was a large piece there - you're pulling the head to get it out - the Borescope is only to see if it's really there.

dirtmover · **Posted:** Sun Oct 04, 2009 3:00 pm

Looks like you can get some fairly small scopes. This for example http://www.fiberscope.net/servlet/the-1 ... %2C/Detail is 4mm which should easily fit into the glow plug hole.

BTW I did the replacement yesterday. There is a crack down the full length of the ceramic tip but still solidly attached. None of it broke away.

#4 is easy to access. Just remove the two nuts holding the filter housing in place, disconnect the electrical connectors and swivel the whole assembly up and out of the way on the rubber lines. Remove the filter housing bracket - 3 nuts. You can then get right into the plug with a 10mm deep socket and a 10" straight extension.

I can also confirm that the Bosch part 80041 is identical the the factory installed plug. In fact, the replacement was manufactured 3 months after the original. I did some more research and just to clarify an earlier comment I made, the Bosch material is quoted in some sources as Inconel 601 which is simply the nichrome wire that the element is made of. This is embedded in ceramic.

jinstall · **Posted:** Fri Nov 12, 2010 10:06 am

Just called the dealer and it seems the GP are no longer avalible. There is a new kit coming out on 20 Nov to replace all the plugs and Mod.

68090434AA is the new kit $166 is the rough price.

Silverdiesel · **Posted:** Fri Nov 12, 2010 1:23 pm

OP, Dirtmover,
See

viewtopic.php?f=5&t=56696

Has good details on actual replacement AND alternate sources to procure new replacement Bosh Glow Plugs.
I got mine from Oxygensensor.net approx $35 incl frieght.

I had #4 go out on me and a while back had to replace #1.... The hardest ones are #2 and 3...but it can be done...

Roland

racertracer · **Posted:** Sat Nov 13, 2010 12:02 pm

Here you go.

viewtopic.php?f=5&t=55535&hilit=glow+plug

Glow plug #4 - how easy? and P/N?

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