Glow Plug System -- e350 & e450 Ford Cutaway E350

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Scheme 7

The 6.0L diesel engine uses a glow plug system that preheats air in the combustion chamber to improve cold engine starting.

The system consists of

1. glow plugs.
2. glow plug control module.
3. powertrain control module (PCM).
4. engine oil temperature (EOT) sensor.
5. barometric pressure sensor (BARO sensor).

The glow plug monitor system is part of the On-Board Diagnostics II (OBD II) System.

The glow plug system is electronically controlled by the PCM. If the oil temperature is below 55°C (131°F), the PCM will energize the glow plugs immediately after the key is placed in the ON position. Then, depending on the readings from the EOT sensor and the BARO sensor, the PCM determines how long the glow plugs will be on.

Scheme 8

The glow plugs are located in the cylinder heads, under the glow plug wiring harness.

The glow plugs are self-regulating. If the engine oil temperature is above 55°C (131°F), the PCM will bulb-check the WAIT TO START lamp but not energize the glow plug relay.

The glow plug ON time varies from 0-120 seconds depending on battery voltage, engine oil temperature and barometric pressure.

The glow plug ON time is independent of the wait to start lamp ON time.

The glow plug control monitor (GPCM) system is designed to find failed glow plugs or failed wiring in the glow plug system.

See INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL articles.

Special Tool(s)

SPECIAL TOOL Remover/Installer, Glow Plug Connector 303 - 1114

Material

MATERIAL SPECIFICATION

Scheme 9

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Scheme 14

1. Remove the retainers and the air deflector.
2. Remove the power steering reservoir bracket retainers.
3. Remove the power steering fluid indicator and retainers. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position the power steering reservoir aside.
4. Disconnect the coolant hoses from the air cleaner outlet pipe.
5. Loosen the clamps and remove the air cleaner outlet pipe.
6. Disconnect the powertrain control module (PCM) electrical connectors.
7. Remove the bolt and PCM.
8. Using the special tool, remove the glow plug harness as needed.
9. Remove the glow plug. No. 7 and 8 glow plugs
10. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
11. Using the special tool, remove the glow plug harness as needed.
12. Remove the glow plug.
13. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
14. Using the special tool, remove the glow plug harness as needed.
15. Remove the glow plug
16. Remove the LH exhaust manifold. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
17. Using the special tool, remove the glow plug harness as needed.
18. Remove the glow plug.

Scheme 15

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Scheme 19

1. Install the glow plug.
2. Clean the O-ring seals and apply clean engine oil.
3. Using the special tool, install the glow plug harness.
4. Install the LH exhaust manifold. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
5. Install the glow plug. No. 1, 3 and 5 glow plugs
6. Clean the O-ring seals and apply clean engine oil.
7. Using the special tool, install the glow plug harness.
8. Install the glow plug.
9. Clean the O-ring seals and apply clean engine oil.
10. Using the special tool, install the glow plug harness.
11. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
12. Install the glow plug.
13. Clean the O-ring seals and apply clean engine oil.
14. Using the special tool, install the glow plug harness.
15. Install the PCM and bolt.
16. Connect the PCM electrical connectors.
17. Install the air cleaner outlet pipe and tighten the clamps.
18. Connect the coolant hoses to the air cleaner outlet pipe.
19. Remove the power steering fluid indicator. Position the power steering reservoir mounting bracket. Install the retainers and power steering fluid indicator.
20. Install the power steering reservoir bracket retainers.
21. Position the air deflector and install the retainers.

Scheme 20

Scheme 21

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
3. Disconnect the glow plug module electrical connectors.
4. Remove the nuts and the glow plug module.
5. To install, reverse the removal procedure.

SPECIAL TOOLS Remover, Glow Plug Sleeve 303 - 764 Installer, Glow Plug Sleeve 303 - 763

Scheme 22

Scheme 23

MATERIAL SPECIFICATION

Scheme 24

Scheme 25

1. Remove the cylinder heads from the engine. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Remove the lifting bracket from the cylinder head.
3. Thread the glow plug sleeve removal tap into the glow plug sleeve.
4. Install the glow plug sleeve removal tool into the threaded sleeve and tighten. Use a wrench to thread the tool into the sleeve until the sleeve is extracted.
5. Clean the glow plug bore with a stiff wire brush. Use filtered compressed air to remove foreign material from the glow plug recess.

Scheme 26

Scheme 27

1. Verify that the glow plug bore is completely clean and dry.
2. Apply Threadlock 262® sealant to the glow plug sleeve in the two places see scheme 42
3. Install the glow plug sleeve into the glow plug bore until it bottoms.
4. Clean the glow plug sleeve after installation with a nylon brush and solvent. Make sure Threadlock 262® sealant is cleaned out before it hardens.
5. Install the lifting bracket on the cylinder head.
6. Install the cylinder heads. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450).

See also:
• INTRODUCTION - GASOLINE
• INTRODUCTION -- 6.0L DIESEL
• INTERIOR TRIM AND ORNAMENTATION
• JACKING & LIFTING
• ENGINE - 6.0L DIESEL
• BATTERY, MOUNTING AND CABLES
• GLOW PLUG SLEEVE