Glow Plugs: Removal

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

RH glow plugs

NOTE: Use a six point socket squarely seated on the retaining nut for removal.

For automatic transmission equipped models, remove the retaining nut and position the transmission fluid indicator tube aside.
Discard the retaining nut.

Fig 1: Locating Transmission Fluid Indicator Tube Nut
Remove the RH fender splash shield. For additional information, refer to BODY PANEL SYSTEM - FRONT END BODY PANELS -- EXCURSION & F250-F550 SUPER DUTY .
Trim the evaporator case to provide glow plug buss bar removal clearance.
Measure and mark a line just below the bottom rib on the evaporator case, from the RH edge outboard toward the wheel, 10 mm (0.39 in) to 15 mm (0.59 in). From that point mark a line downward at a 45 degree angle toward the outboard side of the vehicle.

Using a carbide burr bit and a 90 degree angle grinder, remove the corner.

Fig 2: Trimming Evaporator Case

All glow plugs

NOTE: RH shown, LH similar.
Disconnect the glow plug electrical connector.

Fig 3: Locating Glow Plug Electrical Connector
Remove the glow plug buss bar.

Fig 4: Locating Glow Plug Buss Bar

NOTE: If coolant is found on the glow plug, a new glow plug sleeve may have to be installed. For additional information, refer to Glow Plug Sleeve .
Remove the glow plug.

Fig 5: Locating Glow Plug