white smoke coming out from the heater buster

[maysani]

Sorry this in the wrong form, hope this is the right one
There is a lot of white smoke coming out from the heater buster, it used to happened nearly every month and now it happening nearly every other day particular early morning. What  and how east can be fixed. Is it to do with heater buster igniting plug!
galaxy 1.9DTI 2003

[Chrispb]

Hi Maysani

Have moved your post, changing the glow plug in most instances fix the problem.

Have you looked at the "how to" below

https://www.fordmpv.com/smf2/reference-library/galaxy-mk1-mk2-replacing-booster-heater-glow-plug-on-d3wz-d5wz/

[maysani]

Chris
Many thanks for the reply. Do you know where of glow plug. I found one on eBay (see below link)  but the part number is different from the one you mentioned (VW 7D 0963319 )

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=130560388367&ssPageName=ADME:X:RTQ:GB:1123

part number is LP046

[Chrispb]

That one on your link is not a booster heater glow plug.
This is the one you need, http://www.ebay.co.uk/itm/Eberspacher-glowplug-D3WZ-D4WZ-D5WZ-water-heaters-12v-/270916814954?pt=UK_CarsParts_Vehicles_BoatEquipment_Accessories_SM&hash=item3f13e6886a

http://www.ebay.co.uk/itm/EBERSPACHER-BERU-GLOW-PLUG-GH-001-GALAXY-ALHAMBRA-auxiliary-heater-FREEPOST-/170980692899?pt=UK_CarsParts_Vehicles_BoatEquipment_Accessories_SM&hash=item27cf3e53a3

[maysani]

I cracked open the auxiliary heater of my Galaxy today to replace the glow plug,  to my surprise I found the connecting wires are  spot welded on the plug, the white to the core of the plug and the black to the body, See pics, is this normal I have never seen a plug connected this way? And how to take off  plug now? The one I bought is the one in the link recommended by Chris (noral one with threaded head). [attachimg=1]

[maysani]

the below is a better picture, I would highly appreciate any help as am very puzzled as to why the terminals are spot welded to the plug, unless  I am barking up the wrong tree.  [attachimg=1]

[Mirez]

Hi, this is an 03 Galaxy? I have seen this type of plug but its normally only fitted to the very late mk2's ie 05/55. Any evidence the whole heaters been replaces before?

IIRC the two options are to get the right plug and then chop and join the wires to the existing ones or, if there is enough slack on the current cables, chop them next to the weld, fit crimp rings and use the plug you've got (This is personally what I'd do)

[maysani]

Many thanks for the reply, it is 2003 tdi. I still can not understand your suggestions:-

1)   do you mean chop the wires from the existing one (old one) and spot weld them to the new one,  if so , how would you screw the plug in, the wire will tangle, you need to turn it do not you?

2)   if I chop the wire and use crimp ring, I assume the white  wire will be screwed  to the core of the plug where the black wire will fit? Can you please elaborate more please.

My question now is if they made the plug this way then it means it is for life it will not be replaced Or do I have to replace the whole unit which is very stupid.

[Mirez]

Well I cant say definitively how/why they designed it like this but I do believe it was expected to last the life of the heater. The problem was that these heaters are usually used on boats, motorhomes and trucks where they run for hours at a time. In our environment they can run in short little bursts and lots of starts/stops which degrades the life of the plug.

1) It would indeed need to rotate. Cut the old wires, Spot weld two new wires to the plug, fit the plug and then join the old and new wires together.

2) Take a look at the last photo in the how-to, you would need to get the correct insulated ring clamp for the black wire. That said, in theory at least, the plug's supply is the central terminal. The ground is provided by the body of the plug so anywhere on there OR since the plug screws into an electrically conductive surface, anywhere nearby.

[maysani]

Dear Mirez.
Many thanks for the clarification

What surprise me is that  it works fine for three months or so then starts producing  white smoke for every week for two to three weeks then it works ok for a while. Are they temperamental? or why they go they go.  I also noticed the it come one not at 10 degree and below,  it come on at 12.5 degree,  is that normal ?

[Mirez]

They are a little yes, it's a very simple heater really so fluctuations in voltage, fuel, air, outside temperature and even barometric pressure have an influence. Excess smoke is normally because the diesel isn't igniting which can be because there is too much. For example, if the heater tried to fire but didn't there will be some diesel in the chamber, if it then fires - all that excess will billow smoke.  So yes, they breakdown and its not always an instant fail.

Temperature wise, the sensor is a crude thermo-switch so the trigger temperature will vary from car to car - typically its about 11*c +/- 2*c

[Chrispb]

Hi Maysani
As Mirez has pointed out you have the latest ceramic plug fitted to your heater now this could be that a replacement heater has been fitted or this new type plug has been fitted to an older heater which as you can see in the photo has the leads already attached to the plug.
So to remove the plug you need to remove the terminals from the multiplug, unfortunately to use the older type plug properly you would need to obtain the insulated ring terminal but could be improvised by cutting the centre wire (white) from the old plug and crimp on a correct size ring terminal and use two nuts to lock the white lead to the new plug, the black wire would need to be attached to the body of the plug for a good connection, you could use a small hose clip for this (not the jubilee type) the ones with a proper screw thread and nut then you can attach the lead to this.

Alternatively you can obtain the later plug with wires attached from VW dealer 7M3 963 319A but considerably more expensive than the first plug.
[attachimg=1]

When you unscrew your old plug look into the chamber for the gauze and seals (picture in the how to)

[Chrispb]

As a point of interest the body of the new type plug with wires is insulated (no earth to body)

[maysani]

Dear Chris and Mirez,
Many thanks for your help very much appreciated. I have no choice but to go with your suggestion an order the one you mentioned from VW,  is it the same one in the picture?

Als what do you mean by ââ,¬Å" When you unscrew your old plug look into the chamber for the gauze and seals (picture in the how toââ,¬Â

Do you mean change them as well?

[maysani]

Hi Chris,
I managed to dismantle the chamber and took out the Gauze off there is a bid chunk missing, see pic could it be this one and the faulty not the plug. I need to re[ace it as well, where can I get hold of one? 
[attachimg=1]

[SilverBeast]

Just for information my 05 Galaxy has a D5Z-F heater fitted which has a different ceramic plug that doesn't screw in (I'm about to re-fit it tomorrow after stripping it, though I believe it probably has a controller issue).

It's the part with the fat brown and white wires near the front of this shot.  It just slots into the cavity behind it.

[attach=1]

(Yes Mirez, I have taken lot's of photo's and will put together a how to later )

[Chrispb]

Just for information my 05 Galaxy has a D5Z-F heater fitted which has a different ceramic plug that doesn't screw in (I'm about to re-fit it tomorrow after stripping it, though I believe it probably has a controller issue).

It's the part with the fat brown and white wires near the front of this shot.  It just slots into the cavity behind it.

[attach=1]

(Yes Mirez, I have taken lot's of photo's and will put together a how to later )

For some reason they call that type a glow pin not a glow plug just to add to the confusion

[Mirez]

(Yes Mirez, I have taken lot's of photo's and will put together a how to later )

Ahh thats what I like to hear Thanks!!

[Chrispb]

Hi Chris,
I managed to dismantle the chamber and took out the Gauze off there is a bid chunk missing, see pic could it be this one and the faulty not the plug. I need to re[ace it as well, where can I get hold of one? 
[attachimg=1]

Here's one
http://www.ebay.co.uk/itm/EBERSPACHER-HYDRONIC-HEATER-D4w-D5w-Glow-pin-plug-atomiser-screen-seals-/181107078321?pt=UK_CarsParts_Vehicles_BoatEquipment_Accessories_SM&hash=item2a2ad2b4b1

[maysani]

Dear Chris,
Improvising makes sense, Hence I will go along with what you and Mirez suggested, because even if I order the original VW (spot welded),  it is still fiddly job at the connection box, beside the cost. Also many thanks for the atomiser screen link.

[jbrocks]

This happened on my Mk2 Galaxy today.  Also found this video on Youtube which quickly runs through changing the glow plug. https://www.youtube.com/watch?v=45Zq9nh8iFo

[steveo59]

Hi, after I replaced my glow plug, and it was running for possibly the first time in years, I got lots of white smoke and it is embarrassing. If you take it for a long run with the auxillary heater running it will burn off the excess diesel and wont smoke anymore. Of course this warmer weather the heater shouldn't be running but you can override the temperature sensor (which is clipped to the windscreen wiper linkage mechanism) by bridging the wires, or removing the temp sensor, extending the wires into the cab and fitting a switch. This way  you can operate, or leave switched off on short journeys, whenever you want, you're in control.