Ford Galaxy - Replacing booster heater glow plug on the Eberspächer D3WZ & D5WZ

[Chrispb]

This job is best tackled with the heater removed from the car but can be done insitu without disconnecting coolant pipes, firstly you will need to raise the rear of the car.
Remove the small exhaust and air inlet pipe from the heater.
Then remove the four bolts holding the heater to the chassis (red arrows)
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Now you can lower down the unit then slide the wiring multiplug up and out of the bracket (green arrows)

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Now remove the two nuts holding the two halves of the bracket together, remove bracket from heater (yellow arrows)

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Now remove fuel pipe (white arrow) and the four fan cover screws (pink arrows) pull off the cover.

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Now remove the four screws from controller cover (blue arrows) and pull back controller slightly so that intermediate cover can be removed first, this will then give you enough room to unplug the controller from the internal loom.

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You can now remove the terminal nut, pull off the cable then unscrew the glow plug.

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This is a MK1 with the D3WZ which doesn't have a strainer gauze fitted.
If you want to also change the strainer on a D5WZ you will need to remove the fuel pipe tube this is held in by the flame sensor.

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External screws are usually torx but early models may have crosshead (phillips screws) and as these are exposed to the weather they can get corroded so give them a good soaking with penetrating oil.
If you decide to remove the heater to work on away from the car make a note of the position of the coolant pipes as they need to fit back in the same position before removal.

Useful part no's

Standard glow plug

VW 7D 0963319 
Beru GH001.  0100 226 340
Eberspächer  25 1864 01 10 00
Ford 1257205

Strainer/Gauze kit

VW 7D 0898885
Eberspächer 25 2121 99 01 13

Ceramic glow plug (wires attached)

VW 7D0963319A
Eberspächer 25 2106 01 10 00
Ford 1417618

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