Replacement off the ZD30 Glow Plugs
Replacing the glow plugs of the ZD30 engine is an important and responsible job and is very successfully combined with many other maintenance jobs for this amazing engine, such as:
- Compression measurement.
- Checking the gaps and adjusting the valves, during which it is convenient to carry out the procedure for replacing the belt
- Cleaning the damper block and intake manifold inlet
- Washing the intake pipeline.
Thus, with the right approach, replacing spark plugs on a ZD30 can be turned into comprehensive engine maintenance,
So, to replace the spark plugs you will need:
- Spark plugs NGK Y-522J(5939) or NGK Y-538J x 4 pcs.
- Spark plug seals x 4 pcs. 13276-2W201
- Throttle body gasket 14327-2W201
- Valve cover gasket (if not changed for a long time) 13270-VC100
- Torque wrench up to 28 N*m
- High Temperature Spark Plug Lubricant
Replacing spark plugs is done with the engine warmed up to normal temperature, so first of all we warm up the engine until the coolant temperature arrow begins to approach the middle. Trying to remove a spark plug on a cold engine may cause you to break it.
We turn off the engine and disconnect the battery terminals.
Disconnect the crankcase gas exhaust hose from the valve cover fitting.
Unscrew the intercooler and disconnect it from the pipes by loosening the clamps. Disconnect the air pipes (without disassembling them into parts) from the damper block and turbine.
Close the turbine outlet to prevent dirt or small objects from getting into it.
Troubleshoot, wash and repair the intercooler or prepare to replace it.
Disassemble the intercooler inlet pipes into pieces for subsequent flushing.
Unscrew the 3 bolts securing the damper block and move it towards the right wing (place it on the fuse block), without disconnecting the vacuum tubes from the damper actuators.
It is better to carefully cover the intake manifold with a rag so that nothing gets into the inlet holes.
Disconnect the connector and unscrew the spark plug supply.
Unscrew the spark plug seals (you can use regular pliers) and carefully, so that nothing falls into the holes, wipe away all the dirt under them, if any remains.
Unscrew the valve cover in the reverse order shown in the picture and carefully remove it.
Before unscrewing the spark plugs, it is advisable to blow out their wells with compressed air so that when pulling out the spark plug the tip does not get dirty with oil, it will become more difficult to determine the conditions under which the spark plug worked and make a conclusion about the operation of a particular cylinder and its injector.
To remove the spark plugs, use a spark plug removal tool. On a warm engine, the spark plugs come out without much effort. Next, each candle is unscrewed by hand and carefully removed.
After unscrewing, each spark plug must be marked with the number of the cylinder from which it was unscrewed.
You can change the spark plugs without removing the valve cover, as well as measure the compression if you have the appropriate adapter
Installing new spark plugs. ZD30
You should always change all the spark plugs at once, and they should be of the same type and manufacturer. Candles must be handled carefully, do not throw, hit, or get dirty, especially protect their tips from impacts and damage.
Before installing spark plugs, you need to clean the spark plug wells from soot. The easiest way to do this is to use a suitable rod wrapped in a damp cloth, which can additionally be moistened with diesel fuel.
If the valve cover was removed, then it is necessary to clean off any possible dirt and deposits on the adjacent surface of the cylinder head, as well as remove the old one and apply new sealant to the places shown in the photo below. It wouldn't hurt to replace the valve cover gasket, the front of which is marked with a tongue with the letters FR.
When filling a new gasket, it may seem that it is longer than necessary, but in fact there is nothing wrong with it, just to fill it properly, you need to do it not in one direction, but start from the corners first, then tuck all the bends under the mounting bolts, and only then fill the straight sections.
Install the valve cover and screw in the new spark plug seals, not forgetting to drop a drop of engine oil into each seal before doing so.
The valve cover is tightened using a torque wrench with a tightening force of 10 - 11 N×m (1.0 - 1.2 kg-m) in the order shown in the picture
