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Old 07-13-2012, 12:29 AM   #1 (permalink)
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Date registered: Jan 2012
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Glow Plug Removal

I have heard horror stories about removing the glow plugs on diesel engines and in all my years of removing them I have never had a problem...till today!
This car is the E300D 1995 . I have had the manifold off for 4 days now tracking down and waiting for new Fuel lines and have sprayed the glow plugs every day a few times with penetrating fluid. The first four came out with absolutely no problem and while I was patting myself on the back for being so clever the 5th and 6th glow plugs seemed welded in place literally they didn't budge and after having worked on these things for many years I could 'feel' something was going to break and then there would be a huge problem.
I got out the torch and after two hours I was able to get the last two out.
I'm wondering if others here have had this problem and what they did to get them out?

heating them, spraying them, wrench back and forth, heat, spray, wrench etc... seemed like 50 times for each one. I used some asbestos for insulation and was fortunate to not burn any wiring.

I did cut the end off of the one hidden behind the oil canister to make it easier to get the socket on and off.

Now I'm going to braze a nut on the end of a numbered drill bit and make a 'ream' for the carbon build up. I can't wait to order one from Baum or Hazet.
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Glow Plug Removal-e300d07_13_2012-1489.jpg   Glow Plug Removal-e300d07_13_2012-1490.jpg   Glow Plug Removal-e300d07_13_2012-1494.jpg  
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Old 07-13-2012, 06:19 AM   #2 (permalink)
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Many people have glow plug issues

Many many people have issues getting glow plugs out of the 606 engine. Search here and at peachparts to see all the threads. It's a problem to this engine Glad you were successful.

I'm about to replace plug #1 on my E300, and your efforts remind me to be careful.

Which two plugs were the stuck ones?
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Old 07-13-2012, 08:12 AM   #3 (permalink)
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Quote:
Originally Posted by ds190 View Post
Many many people have issues getting glow plugs out of the 606 engine. Search here and at peachparts to see all the threads. It's a problem to this engine Glad you were successful.

I'm about to replace plug #1 on my E300, and your efforts remind me to be careful.

Which two plugs were the stuck ones?
Counting from the front of the car, 5 and 6.
Thanks for the link!
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Old 07-13-2012, 08:30 AM   #4 (permalink)
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Usually the problem I heard abut it the tip of the plug widens with overheating and even the plug turns, it will brake off the tip, or thread.
Sounds like in your case it was frozen threads?
We put last 60k miles from 230k on our W210 and I am not touching the plugs (knock on the wood).
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Old 07-13-2012, 03:13 PM   #5 (permalink)
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The OM606 is known for this issue, usually resulting in broken off glowplugs.

The main reason is that the glow plug is too long and a bit too skinny. With the buildup of soot on the plug body, the glow plugs can seize inside the head.

That's the main reason why I advocate pulling the glow plugs on any OM606 every 50K, at a minimum.

Replace the plugs or renew using Bosch or Beru plugs exclusively and the most important step is to use Lubro Moly LM508 copper anti seize on the plug body. The lubro moly antiseize is the best prevention I've come across to minimize the glow plugs getting stuck or breaking off in the head.

Be sure to ream the prechambers using the long special tool for the OM606.

Check these links

PeachPartsWiki: Broken Glow Plug Removal

PeachPartsWiki: Broken Glow Plug Removal

Last edited by sbaert; 07-13-2012 at 03:18 PM.
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Old 07-17-2012, 01:22 PM   #6 (permalink)
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Date registered: Sep 2006
Vehicle: '95 E300D
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Quote:
Originally Posted by ds190 View Post
I'm about to replace plug #1 on my E300, and your efforts remind me to be careful.
i had to remove the intake and egr components to get to the plugs, so youre best off (in my opinion) doing all 6 while youre going through that trouble already.
and buy the reamer tool before you start, so youre ready to put the new plugs in right away. i was amazed at how much buildup the reamer removed... the new plugs wouldnt have been long for this world without cleaning as they would have likely gotten carbon buildup all over them as well.

i did a little bit of heat and penetrating fluid and mine came out without too much fuss. i had 4 bad ones though.
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