Glow Plug Relay Control Location 1.6D

[wynnj]

Originally Posted by Ghenti

The dealer has diagnosed a fault with the glow plug relay controller (ecm - 6620) and, as a precaution, they want to replace the 4x glow plugs. However, if they break in the removal process, I will have to pay £3,000 for the a new engine head. Apparently I also cannot replace the glow plug relay controller myself because it needs to be programmed by the dealer, is this true?

ECM 6620 for me was 4 open circuit (dead) glow plugs. I removed the relay and tested it as described in previous reply and it tested OK. It's a relay; there's nothing to proramme with it. Sounds like a really dodgy main dealer.

[wynnj]

Originally Posted by VolvoRob38

Hi, thought Id chime in here and follow this thread as I have the same error on my C30 1.6d 09. Been meaning to get back onto it for 12 months.

I had my front bumper off looking for the relay, but turns out mine is also located in the fuse box infront of the battery in engine bay (photo). I bought a new one from Volvo for about £13. Turns out there was nothing wrong with the old one after talking it apart and connecting to a 9v battery, the gate open/closed as expected.

So I tested the 4 glow plugs (whoever designed the engine is a nob for putting the at the back. Nightmare!) Using a multimeter which all came back with acceptable readings, I forget the ranges now. There might have been 1 that read lower than the rest, but still in range. I want to try changing the glow plugs as thats a cheap job... unless they snap in the engine, which is a bit off putting tbh. Ive read you need to warm the engine up first and then pray.

My mates works for AA and put his computer on it, but that just came back with the same error as my vida, and testing the plugs using Vida shows I am not getting the correct volts when starting the engine.
My mate sent me the wiring diagram to try and trace any breaks back, but a bit complicated to say the least.

My next test is to see if I'm getting 12v to the glow plug connectors when the engine turned over, but not sure if I test 1 at a time or remove all 4 and test. Will the engine still start?
Thats where I was upto last summer. If I'm getting 12v then its probably the glow plugs. If Im not getting 12v then it must be either the wiring itself or further back on the otherside of the relay.

Its a tricky because Ive read people on here paying out hundreds of £ only to find out that doesn't fix the problem. The computers/vida is good, but its not pin point accurate. Limited sensors I guess.

If I remember correctly from troubleshooting mine, the 4 glow plugs are all connected in series to the one supply and with the relay removed you can do a continuity test from the relay socket to the glow plug connectors.
Not sure that the supply voltage to the glow plugs is 12v; I think I measured a lower value but can't remember - perhaps someone else can confirm.

I agree completely with the nob engineering. I had a rant about it a couple of months ago! https://www.volvoforums.org.uk/showt...=322987&page=2

If you do decide to change them your yourself spray them with penetrating fluid for days before hand (I used several different ones in the hope that at least one would have some effect) and use a torque wrench set in reverse mode to no more than 20nm to undo them. Once one moves work it back and fore until it unscrews all the way. Good luck.

[VolvoRob38]

Originally Posted by wynnj

If I remember correctly from troubleshooting mine, the 4 glow plugs are all connected in series to the one supply and with the relay removed you can do a continuity test from the relay socket to the glow plug connectors.
Not sure that the supply voltage to the glow plugs is 12v; I think I measured a lower value but can't remember - perhaps someone else can confirm.

I agree completely with the nob engineering. I had a rant about it a couple of months ago! https://www.volvoforums.org.uk/showt...=322987&page=2

If you do decide to change them your yourself spray them with penetrating fluid for days before hand (I used several different ones in the hope that at least one would have some effect) and use a torque wrench set in reverse mode to no more than 20nm to undo them. Once one moves work it back and fore until it unscrews all the way. Good luck.

Cheers for this Wynn, I just want to confirm that its not the wiring before attempting to remove the plugs, but will defo keep your advice in mind re the penetrating fluid. Im guessing from that advice you have successfully replaced yours. If it come to it I probably will have a go myself, when it gets a bit warmer and my hands can take the beating fiddling at the back of the engine lol.

Re testing the plug connectors, they are all on one cable, so I guess I can just remove one to test. Unless the problem happened to be in one of the individual plug connectors. Super unlucky if it were to be lol.
Im pretty sure I tested for continuity from the relay to each of the 4 plug connectors, all ok. Because testing the plugs via vida shows a lower than expected voltage (i forget what it should be now, it tells me in vida when testing) I was thinking I need to test plug connectors while the relay is in place and the ignition started to know if I am getting the required volts at the plug connectors when the engine is started, and if I do I assume faulty plug(s), and if I am not getting the correct voltage and the relay is ok, then my issue might be between the relay and, im guessing, the battery.

Cheers
Rob

[Ghenti]

Thank you all for your help. I found a local Volvo specialist who is going to replace 4 glow plugs and the glow plug relay controller (if required) for £390, with Volvo parts.

Hopefully this resolves the issue. I will update this post when the repair is completed.

[VolvoRob38]

Originally Posted by Ghenti

Thank you all for your help. I found a local Volvo specialist who is going to replace 4 glow plugs and the glow plug relay controller (if required) for £390, with Volvo parts.

Hopefully this resolves the issue. I will update this post when the repair is completed.

Just wondering... did the new glow plugs solve the issue??

[Ghenti]

Originally Posted by VolvoRob38

Just wondering... did the new glow plugs solve the issue??

Will change the glow plugs Friday. Will update next week

[Ghenti]

The glow plugs and relay was changed and all fault codes reset. None of the glow plugs snapped while removing them. Currently I do not have any warnings on the dashboard.

Thank you all for your help. I will provide another update in two weeks.

[Ghenti]

Update. Car has been driven for a month and I do not have warning lights on dash.