Glow Plug failure and Fix!

Silverdiesel · **Posted:** Mon Sep 21, 2009 9:29 pm

Glow plug #1 : failure and fix
Starting off by stating this problem started the same time LOST went off air and fix was all done went LOST came back up Today!!
Failure : Persistent CEL and pulling code I got P1261 "#1 glow plug volts low"
CEL stays on and that is annoying as glow plugs are an afterthought when afternoon temps out here are 105 degrees plus!

Condition/ cause : glow plug failure and did resistance test and all plugs were .8 to 1.0 ohm but plug #1 (front one) was 5 ohms. That very plug is the easiest to get to, straightshot with a 10mm deep socket with 10 inches of extension, 1/4" drive right behind alternator.

Fix : got replacement OEM, Moparpartsamerica.com P/N 5142577AA $40 plus freight. Used plug boot puller to pull wiring boot off plug. The glow plug is the size of a skinny ball point pen and must be REAL careful not to touch or drop ceramic end even from 2 cm's as damage/ failure will result. Carefully insert into head like you are playing "Operation" by not touching or dragging said ceramic end 6 or so inches till treads meet up and torque to 10 Inch/Pounds. Test and clear code and since Can OBD II reader/scanners produce false "ABS" and "U" connection codes , CEL stays on for approx 4 or five starts. Now I have what I call a clear board!

BTW looked up DTC P1261 on LOST CRD Tech the nite before crash and tried numerous other Jeep and Dodge and Chrysler sites to confirm this code and NOONE had this code # listed - only LOST!- This site is way beyond valuable- it is indispensable--thanks LOST. This is main reason I post up in detail my fix - to be able to help fellow LOSTer/ CRDers.

BTW #2-searching history on this DTC shows that DarbyWalters lost an engine due to this problem as the glow plug end failed and shattered and threw debris into the combustion area, exhaust valve and outtake and into the turbo! He had warranty cover as this happened at 8K miles. So I got lucky I did not get a shatter! I am at 80K miles.
Roland

AZKJ · **Posted:** Mon Sep 21, 2009 9:37 pm

That's a very good write up!! Any tips for us gassers???

Silverdiesel · **Posted:** Mon Sep 21, 2009 9:43 pm

Yeah you notice I did not call that bootpuller a "sparkplug boot puller"- I would have had to scrub my hands and keyboard with scouring soap - Patoowie!!
We use glow plugs - we don't need no stinking spark plugs!

Silverdiesel · **Posted:** Mon Sep 21, 2009 9:46 pm

"We don't need no stinking spark plugs!"
http://i259.photobucket.com/albums/hh28 ... badges.jpg

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

How did the ceramic tip look on the old plug, as in was it intact and not missing any pieces? When my 2 gp's failed, they showed them to me and they were in perfect physical condition, but that was at 8K miles.

MrMopar64 · **Posted:** Mon Sep 21, 2009 10:24 pm

I find it interesting that the issue of glow plugs breaking has been brought up again because I've seen a lot of cases of this lately and they're always the #1 GLP.

To anyone that's had an issue with this, the root cause so far seems to be the glow plug control module that has actually failed and is improperly modulating the voltage to the plug. Just as an FYI, glow plug failure is always attributed to a sustained over-voltage condition.

The glow plug module is P/N 56044671AC and is $26 from moparpartsamerica. If you've been plagued with a single GLP failure, I would recommend to replace this as well since it is cheap insurance against future failures.

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

The reason I ask about the condition of the old gp is because VW has recalled all of their Bosch ceramic glow plugs (listed as an emissions related recall) and is replacing them with 5 Volt DC metal gp's. VW owners attempting to purchase ceramic gp replacements are being told that the old ceramic gp has been replaced by a new metal tipped one and the ceramics are no longer available. This lower voltage gp requires a flash to change the duty cycle or else the new 5 volt gp's will burn out very quickly, as a few VW owners discovered. The VW community is also experiencing a certain percentage of broken ceramic tips.

Silverdiesel · **Posted:** Mon Sep 21, 2009 10:40 pm

Ranger1 - Tip looked intact- just burnt charred looking- displayed a darker hue than new one.

MrMopar64 - GP module replacement is a good idea - glow plugs 2 through 4 look awfully tough to get to.

AZKJ - JK Sir !!, always like to throw out that no spark plug joking/ humor.

vegiH · **Posted:** Sun Sep 27, 2009 12:28 am

did all GPs and relays 4000 miles ago (and turbo,headgaske and two rockerarms with timing belt),and darn P1263 is back..........WTF>>>>>>>>>>>>>>>>>>>>could it be the relay connector is loose?

GreenDieselEngineering · **Joined:** Sun Jun 07, 2009 5:10 pm **Posts:** 1111

Can you check your software level in the engine controller? If you do not have either of the following part numbers then your calibration is older and does not have the TSB fixes installed for the glow plug temp governing. 56044562CE (TSB 18-009-06) in Dec. 2005 or 56044562CF (TSB 18-023-06) in June 2006.

A scan tool may be able to read this or a Jeep dealer for sure. Without either of these TSBs you risk random glow plug failures for the life of the vehicle. That is not to say that the TSB cals fix all the problems, but they certainly reduce the possibility of a failure.

Good Luck.

vegiH · **Posted:** Mon Sep 28, 2009 3:35 pm

Its going in @3 on thursday for glowplug TSB,which one do I want ? or does one supercede the other?What exactly do they need to plug into? I only ask because this a WVO burning,Edge programmed, SEGR equipped rig....................Not much left stock.............here kitty kitty.Thanks for the help,let me know when you (GDE) have a program that advances timing 12 degrees.as this is ideal for WVO use.........H

GreenDieselEngineering · **Joined:** Sun Jun 07, 2009 5:10 pm **Posts:** 1111

Have them put in the latest as it includes a base software update in case your vehicle does not already have it, it should have supercedence anyway.

The tunes we offer already include advancing the injection timing between 8 to 13 degrees depending on rpm and load. This along with increasing boost pressure and modifying the pilot injections were the core to achieving the bulk of the increased fuel economy. We would not recommend stacking aftermarket tunes and chips, since you already have a chip. Stacking may increase the cylinder pressure beyond the design limits at wide open throttle. Our products already have provisions to increase the fuel pressure to its max, mixing with the trailjammer might cause an issue long term.

Good luck with the glow plug fix.

dcxman · **Joined:** Mon Apr 17, 2006 8:09 am **Posts:** 4

I have been plagued by the 1261 also. The shop replace the module and the replacement plug immediately burned out.
Now they say I have engine damage evidenced by coolant in the exhaust.
They still can't explain what is going on with the glow plug.
Bringing baby home.

Ripster · **Posted:** Sat Oct 24, 2009 9:37 pm

I spent most of Friday afternoon at a Dealership in Wisconsin. The technician began with testing and we ran out of time..Going
back in next Friday as he wants to remove parts in his way to get at the complete harness, and each glow plug. He thinks the
wires may be switched or incorrect. He wants to trace each harness to ensure that #1 is on #1 because we have replaced #1
and the module last week at another dealership and the code came back. So the alternator, and brackets for the EGR or FCV
will be removed so he can get at all 4 plugs and the harness. I have the extended warranty, so at 44k with 100 deductible
I just hope we can put this glow plug issue to rest. Will keep you posted. While I was there he mentioned that one of
the CRD's the dealership sold has over 200k but the owner has never brought it to them for a timing belt change. Can't
wait to hear how that works out.

Joe Romas · **Posted:** Sun Oct 25, 2009 7:59 am

Ripster wrote:

I spent most of Friday afternoon at a Dealership in Wisconsin. The technician began with testing and we ran out of time..Going
back in next Friday as he wants to remove parts in his way to get at the complete harness, and each glow plug. He thinks the
wires may be switched or incorrect. He wants to trace each harness to ensure that #1 is on #1 because we have replaced #1
and the module last week at another dealership and the code came back. So the alternator, and brackets for the EGR or FCV
will be removed so he can get at all 4 plugs and the harness. I have the extended warranty, so at 44k with 100 deductible
I just hope we can put this glow plug issue to rest. Will keep you posted. While I was there he mentioned that one of
the CRD's the dealership sold has over 200k but the owner has never brought it to them for a timing belt change. Can't
wait to hear how that works out.

It's been posted here before that at least some CRD's have two glow plug wires switched :wink:

ATXKJ · **Posted:** Sun Oct 25, 2009 9:09 am

Why would it matter?

the Glow plug module turns them all on and all off at the same time.

the code will be different - but that's why you check the resistance before you pull the glow plug.

flman · **Posted:** Sun Oct 25, 2009 9:25 am

From what I can see, the relay has one heavy ga wire in, and 4 lighter ga wires to the plugs. Can the DTC scanner read which cylinder the malfunctioning GP resides in? I know it can on a VW TDI, but that little Bosch relay on our CRDs does not look all that smart to me?

Ripster · **Posted:** Sun Oct 25, 2009 9:58 am

It would not except he wants to check the harness and he can not reach #2 and #3 with his hands I guess.
The amount of space is really limited from what I see.

dirtmover · **Posted:** Mon Oct 26, 2009 5:35 pm

ATXKJ wrote:

Why would it matter?

the Glow plug module turns them all on and all off at the same time.

the code will be different - but that's why you check the resistance before you pull the glow plug.

I guess it would matter if you have to pay 2.5 hours labor to get to the point where you can make a resistance measurement on #3 only to find out the bad plug is really #4 which takes another 30 minutes to access. Could get kind of expensive if this isn't warranty work.

Ripster · **Posted:** Mon Oct 26, 2009 6:30 pm

I have an extended warranty and looks like
I will be putting it to use as this is the
3rd visit on the plan not for this issue but
other minor electrical issues. The mechanic is
going in to check them all so will know
late this Friday.

Glow Plug failure and Fix!

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