Greetings,
I'm going to change the glow plugs in my 94 7.3 turbo diesel.
Is there any suggestion or technique to changing them? TO work around or through the clutter on top of the engine, and especially under the Turbo?
Note: every parts store I went to swore that the glow plugs were under the valve covers. They are not.
So, any advice on this project would be appreciated.
Thanks,
Greg P.

 

I just changed a set of glowplugs on my 93' factory turbo 7.3 and it is a chore doing the 2 plugs under the turbo but with the exact extensions on a deepwell 1/4" drive it can be done. First remove the air intake, disconnect the bat. leads, remove the air filter, air bo2 bolts holding it on the intake), and the glow plug controller from the valve cover bracket, and the injector support clamps which block access to the glow plugs(1 on the right bank and 1 on the left bank). These are the clamps that have a rubber pad squezzed by a metal clamp bracket to space and secure the injector lines. After these items are out of the way you can get at all the glow plugs for removal. Not without some frustration! I replaced my plugs with the ZD-9 Motocraft stock ones. All seems to be working well now and the timing of the glow plug controller is now normal. Starting is instant after the controller times out.
Lots of luck!

 

Hey thanks Jakester!! I have to replace at least 1 glow plug, and have not checked the two under the turbo yet. I was dreading taking the turbo off just to check, then worse replace them. After reading your advice, I'll probably save myself alot of time messing with the turbo....

BTW, Gregmp. I usually just tell the parts stores I have either a '93 (for turbo related parts, or parts I know I need the serpentine belt for, or the body style parts) or a '91 7.3L engine. Otherwise, they hear the '94 portion of the 7.3L diesel and assume it is a powerstroke, which does have the glow plugs under the valve covers.

 

Being the new owner of an early 94 F250 myself, I'll hafta remember this!

I was confused about it the PSD vs IDI thing afore I got one, I'm sure that people that don't hafta deal with em on a regular basis are ALL screwed up!

M

 

Your truck is definetely an IDI. It was the early PSD's that had the glow plugs under the rockercovers

0.0 Clean off the top of your motor (air blow or steamclean) to move any debrie that could fall into the cylinders when you remove the glow plugs.

1.0 Buy only good Ford glowplugs (BERU, Made in Germany)

2.0 Changing the plugs on the Drivers side and the two front plugs on the passenger side is pretty strainght forward once you remove the inlet housing to the turbo. Also unbolt and move the glow plug controller unit to the side. (Makesure your batteries are disconnected while you do that to avoid an accidental short with the live power terminals on the GP controller. A couple of bolts, no big deal. It helps to grind off about a 1/4" of a standard deep socket, this will avoid having to move any of the injection lines or line clamps.

3.0 The real problem are the two glow plugs under the turbo. Getting the electrical connectors pulled off and put back on can be a challenge as there is very poor access. Careful not to damage the connectors with a screwdriver or needle nose pliers.

4.0 Once you got the connectors off, use the same deep socket from Step 3, a 3/8" universal joint and some extensions to get the plugs loose. I found the back glowplugs to be easier accessible from the drivers side of the turbo with a double long extension. Once loose you can use a piece of 3/8" or 5/16" fuel hose, slide it over the plug and screw it out. Also use 3/8" hose to fiddle the new plugs back into the hole and get the thread started.

I usually spent 15 minutes getting the air intake off and changing the six easy plugs and then fiddle around for an hour with the two plugs under the turbo.

Note, it is not worth removing the turbo, it just takes a little patience and knowhow to change those two plugs under the turbo.


Seb.....

 

in between the blowing off the top of the engine and the unscrewing of the plugs, spray them liberally with pb blaster, and let it soak in for a while. it will make the removal a lot easier.
before installing the new plugs, give the threads a coat of never-seize. it will help them go in, help seal the threads, and make replacement easier when you have to do it again in 15 years.
as far as the parts store, if you have a 94 idi, just tell them you want BERU/ MOTORCRAFT ZD 9 glow plugs.

if they ask what it is for, tell them you only want those plugs. if they insist they must know what you are working on, tell them it is a 1921 model TT pickup. then when they tell you that it don't use them, you can tell them you know what you want, and you will accept no other substitutions, cause they are the only glow plug that will work in what you are working on.

i have done this a few times. when the jerks realize i will not tell them what i am working on, they will get me what i asked for, or i will take my business someplace that will give me what i want, not what they want to give me.