2004 E60 530D Glowplug Controller Replaced

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2004 E60 530D Glowplug Controller Replaced

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Thread: 2004 E60 530D Glowplug Controller Replaced

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2004 E60 530D Glowplug Controller Replaced

29-09-2012, 15:04

At last got around to changing my Glowplug controller. Had the car 10 Months and had Glowplug errors since I have had it.

#1

chr15gb

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When I got the Swirl Flaps removed I had all 6 glowplugs replaced but it only reduced the errors from 5 out of 6 to3 out of 6.

I measured the Glowplugs and got 0.7 Ohms between the centre core and the block (Range is 0.5 to 2.5 Ohm) sothey are all good.

Bought a replacement Glowplug Controller (Beru £79 delivered) and fitted today, all in done within 4 hours butseveral coffee breaks and it wasn't a race!

TIS Guide sounds easy... HA HA!!!! one of the most fiddly jobs I have done. Read some online guides Manifold Off, standard guides as per Swirl Flap Removal

10mm Socket, an 11mm Deep socket and short extension bar for the manifold

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I have no idea how people do this without removing the coolant hose. Three bolts to take out.

I also removed the Starter Motor cable as it runs right across the only space you can get your hand at the plugs.There is another bolt behind the Oil Filter housing which I removed to give a little more flex in the pipes. Now youcan see the damn thing

You can't get sockets on square but they do bite enough to remove and tighten afterwards

I managed to remove the large plug from the controller with the nuts loosened enough to move the controllerabout a bit (but still on the studs), squeeze the clips as hard as you can, they do make a click when the tabs arefree, then withdraw.

The round power one was a swine, I forced a flat bladed screwdriver under the tab (in yellow), turned thescrewdriver to open one side and gently but firmly withdrew this plug (the opposite clip is still housed but came outokay).

Once the plugs are off it is a case of manipulating it through the myriad of pipes

My car is now completely error free

.

Last edited by chr15gb; 20-08-2013 at 18:10.

The Following 5 Users Say Thank You to chr15gb For This Useful Post:

530ben (10-09-2013),ahjclassic (13-03-2013),lmsvvavr (29-09-2012),mjojom (29-09-2012),ssd (07-10-2012)

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29-09-2012, 17:39

nice mate, but 4 hrs even with the coffees is a bit too much well done

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mjojom

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chr15gb (29-09-2012)

29-09-2012, 17:50

ha ha, I did give the EGR a quick clean too but yes, could have done it quicker but I set a whole day aside. If I rushit I normally lose a socket down that black hole my car has.

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chr15gb

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30-09-2012, 01:29

true, rushing this things is no good, very nice guide.thanks

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12-03-2013, 10:57

Chris

i thought you only need to replace the controller if you get errors for every glowplug cyclinder.

This wasn't the case for you was it?

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veeshy

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12-03-2013, 12:40

you need to replace the controller if you get errors reported for known good glow plugs

As its very unlikely that 3 or more will fail at the same time then multiple failed glow plug errors are quite likely tocome from a failed controller

and yes - its a swine to change

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digby

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12-03-2013, 16:57

Thanks Digby

Just had all 6 changed over the weekend and had I know that i might of had the controller replaced too, thought itwas a good idea to get the swirl flaps done at the same time too.

Issit worth while getting the glowplug controller and both thermostats replaced together?

need a new throttle valve also but not sure where or when to get that involved as they don't appear to comecheaply and cant seem to find many used ones.

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12-03-2013, 17:35

the glow controller and thermostats are 2 different jobs

the controller "needs" inlet manifold removal (it can be done without but i wouldn't)

Thermostats change needs the radiator fan out plus a few other bits at the front of the engine

If you do it yourself you can do it as 2 separate jobs

If you are having it done then i guess there is not much money to be gained by doing both jobs together - unlessyou can get a discount from the garage

Are your stats shot or is it preventative maintenance ?

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digby

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12-03-2013, 18:28

Thanks for the advice. Just want to get all the bits done and dusted and not have to worry about the car till theservice is due.

As for the thermostats, they dont seem to reach the 90C anytime soon, im looking at around 45min-1hour.

So based on that i was told defo need them replaced. May carry out another run after work whilst connected toINPA to see what i get.

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Originally Posted by digby

the glow controller and thermostats are 2 different jobs

the controller "needs" inlet manifold removal (it can be done without but i wouldn't)

Thermostats change needs the radiator fan out plus a few other bits at the front of the engine

If you do it yourself you can do it as 2 separate jobs

If you are having it done then i guess there is not much money to be gained by doing both jobs together - unlessyou can get a discount from the garage

Are your stats shot or is it preventative maintenance ?

12-03-2013, 20:08

I woudn't do both stats and controller in one go.

Less than an hour for the stat is very optimistic unless you are experienced with it, there are lots of subtle lessonsto learn which only become apparent afterwards. I wasn't prepared to bend the EGR Cooler up out of the way, I removed the whole cooler complete with exhaustmanifold pipe.

I should have removed the MAF/Turbo pipe to get access easier but didn't think and struggled on with blu tack on

#10

chr15gb

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the end of a socket to avoid dropping it lol.Most just bend the cooler pipe but if that splits, it's another World of hurt to sort out.

You can live with Glowplug errors for now, Stats should be the priority. I wouldn't bother faffing with INPA, if youdon't get to 90 degrees within 10 minutes, they need changing.I can watch mine climb gradually up to 90, then it drops right back down to low 80's (because the stat has opened),then climbs back up again and sits stable at 93 when driving steadily on a motorway.

Some people state any Glowplug errors will prevent a Regen... the jury is out on that one, I have my ownexperience to draw on but for absolutely sure, you will not be regenning with low temps. This means for sure yourDPF is sprinting towards getting blocked every time you drive it.

Having done the Controller - I would love to see how anyone can do that from the bottom or without removing themanifold. Everything is far too congested around it.

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