Hot wire to glow plug

[cambium]

Hot wire going to glow plug nearest to battery has melted the plastic holder through any ideas guys or anyone had same problem. ......should this be a recall job ......its on a 2010 trend

[blue estate]

One of the glowplugs is faulty don't replace wire till fixed as it's a fuse link

[Spike2450]

Had exactly the same thing and is a common issue, if it's under warranty then take it in. It can be caused by high resistance on one of the glow plugs ! I tried disconnecting the first glow plug to measure the resistance and snapped the top off the glow plug wtf, so couldn't be arsed with that, so as the circuit is protected by a fuse all i did was to lose the plastic connector which i believe was causing the poor connection, i cut the connector off, stripped the cable and crimped a connector on it and joined both cables with a nut and bolt, insulation tape and cable tied it back. Been fine for a month.

[gt_addict]

Cheap enough to replace all the plugs, wire and relay (fords guy said it was the relays fault apparently).

[cambium]

One of the glowplugs is faulty don't replace wire till fixed as it's a fuse link

Checked all glow plugs with multimeter all showing same voltage as battery, checked resistance of plug loom from bolt connector to last glowplug zero resistance, glowplug relay clicks when ignition key turned..........wire still getting hot at bolt joint ????

[gt_addict]

Did you pull each pkug out individually and check the resistance. You can't do it while they are in the engine.

[cambium]

Did you pull each pkug out individually and check the resistance. You can't do it while they are in the engine.

Trying to avoid pulling plugs in case I snap one not done it before thought using multimeter positive to positive on battery and touching each plug with negative black multimeter lead reading for each plug was the same voltage as battery voltage......thought that meant plugs were ok ?

[gt_addict]

Ideally you want to check resistance and you can only do that when they are out. My plugs on my 2004 tdci came out easy. Slight pressure on the ratchet and they popped undone.

[doebag]

Make sure you remove the plugs when the engine is properly hot.

[El transito]

One of the glowplugs is faulty don't replace wire till fixed as it's a fuse link

Checked all glow plugs with multimeter all showing same voltage as battery, checked resistance of plug loom from bolt connector to last glowplug zero resistance, glowplug relay clicks when ignition key turned..........wire still getting hot at bolt joint ????

You don't need to remove the glow plugs to test them but you do need to remove the red cable to test them individually. If you have "Open Circuit" (Zero Ohms resistance) when you tested with all 4 glow plugs connected to each other, but not to feed wire then all 4 plugs are faulty. The correct resistance I believe is about .68 on the 200 ohm scale.
To test individually remove one of the nuts retaining the red cable (NO 1 is the easiest to remove so start here) clip the black test lead to ground (An injector pipe) and the red test lead to the thread of the glow plug (Cable now removed). Open circuit = faulty glow plug, any resistance means its working but he lower it is, the less "Glow" it has. Hope it helps

[cambium]

One of the glowplugs is faulty don't replace wire till fixed as it's a fuse link

Checked all glow plugs with multimeter all showing same voltage as battery, checked resistance of plug loom from bolt connector to last glowplug zero resistance, glowplug relay clicks when ignition key turned..........wire still getting hot at bolt joint ????

You don't need to remove the glow plugs to test them but you do need to remove the red cable to test them individually. If you have "Open Circuit" (Zero Ohms resistance) when you tested with all 4 glow plugs connected to each other, but not to feed wire then all 4 plugs are faulty. The correct resistance I believe is about .68 on the 200 ohm scale.
To test individually remove one of the nuts retaining the red cable (NO 1 is the easiest to remove so start here) clip the black test lead to ground (An injector pipe) and the red test lead to the thread of the glow plug (Cable now removed). Open circuit = faulty glow plug, any resistance means its working but he lower it is, the less "Glow" it has. Hope it helps

Yep I removed red plug cable then tested each plug ......checked battery voltage first as a ref and each plug was same voltage as battery

[El transito]

The voltage at the plug will be zero with the cable removed as its the cable that brings the battery voltage, do you mean the resistance was zero? If so the plug is faulty.

[cambium]

The voltage at the plug will be zero with the cable removed as its the cable that brings the battery voltage, do you mean the resistance was zero? If so the plug is faulty.

This is how I did it
https://youtu.be/4TcuJDd9Hho