Replacing the glow plugs on DW8 diesel engine

 I need to replace the heat plugs of the DW8 since my van only start with a cold start spray shot if the temperature goes down or if the dampness is too much.
I had a look today but couldn't figure out how to take the air intake manifold out which is needed cause it blocks access to the plugs.
And lucky me found this from Liamautomechanic!
Thanks Liam!

replacing the glow plugs removing the inlet manifold citeron peugeot video


 If i get it correctly we have to take off and disconnect:

• 4 bolts (HEX wrench/ alen key 5) [b]>[/b]metal pipe from exhaust (screwdriver) 
• flexi pipe 
• electric plug at bottom
• water bottle to be moved out of the way

next step is to remove the nut on top of the heater plug.
He uses a 10 socket and a small ratchet to unscrew the plugs.

hopefully i dont need that:
+++ Day 2: All went well. It took me 2 or 3 hours not counting in the time it took to find the tools (I havent got that many and they re all scattered + when I went to buy the extension for the ratchet the shop employee got the key stuck in the display's lock...). What I needed was slightly different than on the above video which is normal since my engine is on a LDV Pilot 2003 DW8 diesel non turbo. Tools used:

• DW40 lubricant
• short arm HEX wrench/Allen key 5 (not sure of the size though) 
• medium or long arm HEX wrench/Allen key (bigger size but again I don't know exactly 
• flat screwdriver pair of pliers 
• socket 7mm
• deep socket 10mm (for plugs) 
• ratchet 
• ring offset spanner (or deep socket wrench) 8mm light 
• set of new plugs... 

Before anything give the plugs a good DW40 bath...
First unscrew the Allen head bolts.  These with long arm Allen wrench:

 These with the short arm smaller hex wrench

Next unscrew the air intake pipe collar with the flat screw driver.

snap open the clip-on collar of the metal pipe from the exhaust using the screwdriver too.

If you disconnect these two you can already pull out the air intake manifold that covers the engine head and prevents access to the glow plugs.
Then you can start unpluging the flexi pipes (there are 2 of them) and the electric plug. They are located close-by the air intake connection.
You can see the plug here and the red labelled flexi pipe - connected beside each other. Right behind is the third flexi pipe which connects underneath.

The third flexi pipe.

Disconnect that bigger rubber pipe at the very back of the manifold (below the electrical ringed plastic pipes on the image) using the flat screwdriver. Pop it out like the pipe from the exhaust. Same clip-on collar type.

 

Lastly unscrew the bolt that hold these 2 electric wires right under that rubber pipe you just took off. Use the ring spanner or deep socket one 8mm for that job.
They are disconnected on the image.

 
 Pull out the manifold and you can now access the plugs.
Get your 7mm socket and your ratchet + extension to undo the bolts that hold the wire (sometimes a metal plate) between the plugs.

Once undone pull out the wire and change the socket to the deep 10mm one so you can get cracking on the plugs. Go carefully cause it seems they can break easily. I had no probs at all but maybe it was due to the DW40 bath?
It's appropriate to clean around the plugs before you take them out or else just make sure nothing gets in their hole when taken out and when placing in the new ones. A reasonable amount of grease on the thread of the new ones is probably a good idea too.

The old ones on mine looked like that:

No wonder why the engine wouldn't start as soon as the temperature would go down...

Once you re done with the new ones, go all the way backwards:

1. electric cables at the back
2. rubber pipe at the back (bit of a pain to close the collar back - I used a pair of pliers)
3. flexi pipes x 2 by the air intake connection
4. electric plug by the air intake connection
5. Main air intake pipe to the manifold - tight up the collar back
6. Place the manifold where it should be
7. Metal pipe from the exhaust (pain as well -I used a pair of pliers which crunched flesh off my fingers)
8.  Screw back the Allen bolts

 that should tighten up everything.

If you did it correctly and hopefully this was just maintenance, the engine will start up right away as mine did.