Glow Plug Relay Replacement Federal Emissions

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Loosen the outlet duct clamp at the upper intake manifold cover.
3. Remove the upper intake manifold cover from the outlet duct.
4. Remove the upper intake manifold cover.



5. Using a flat bladed screwdriver, disengage the glow plug controller cover clips.



6. Remove the glow plug controller cover.



7. Remove the glow plug relay terminal nuts and wires.



8. Remove the glow plug controller nuts.



9. Lift the glow plug controller off the studs.



10. Separate the glow plug relay from the glow plug controller housing by inserting a small screwdriver between them while prying the relay assembly outward.



11. Slide the glow plug relay outward to disengage it from the glow plug controller housing.



12. Using a flat bladed screwdriver, disengage the glow plug relay clip.



13. Remove the glow plug relay.

1. Install the glow plug relay.



2. Slide the glow plug relay inward to engage it to the glow plug controller housing.



3. Set the glow plug controller onto the studs.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the glow plug controller nuts.

Tighten
Tighten the nuts to 42 N·m (31 lb ft).




5. Install the glow plug relay terminal wires and nuts.

Tighten
Tighten the nuts to 5 N·m (44 lb in).




6. Install the glow plug controller cover.



7. Install the upper intake manifold cover.
8. Install the upper intake manifold cover to the outlet duct.
9. Tighten the outlet duct clamp at the upper intake manifold cover.

Tighten
Tighten the clamp to 6 N·m (53 lb in).

10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

Glow Plug Relay Replacement California Emissions

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Loosen the outlet duct clamp at the upper intake manifold cover.
3. Remove the upper intake manifold cover from the outlet duct.
4. Remove the upper intake manifold cover.



5. Remove the battery supply cable nut (1) and cable from the glow plug relay battery voltage supply post.
6. Disconnect the glow plug electrical connectors (2) from the glow plug relay (3).
7. Remove the glow plug relay bolt (6).
8. Remove the glow plug relay (3) from the bracket (4).

1. Install the glow plug relay (3) onto the bracket (4).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the glow plug relay bolt (6).

Tighten
Tighten the bolt to 20 N·m (15 lb ft).

3. Connect the glow plug electrical connectors (2) to the glow plug relay (3).
4. Install the battery supply cable and nut (1) onto the glow plug relay.

Tighten
Tighten the nut to 5 N·m (44 lb in).




5. Install the upper intake manifold cover.
6. Install the upper intake manifold cover to the outlet duct.
7. Tighten the outlet duct clamp at the upper intake manifold cover.

Tighten
Tighten the clamp to 6 N·m (53 lb in).

8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.