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  #1  
Old 10-20-2004, 07:15 PM
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Join Date: Nov 2003
Location: Ohio
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Glow Plug Changing - '92 300D

Can anyone help me with changing my glow plugs. I have a '92 300D 124 602 engine. I can barely see them much less get in there and change them. My old '83 300D was a piece of cake....but this???? Are there any tricks or tips? What needs to be removed? Can a backyard mechanic do this or am I getting myself into trouble? Any help would be greatly appreciated.

Thanks, dtimmester

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Old 10-21-2004, 06:47 AM
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Join Date: Jul 2004
Location: Sydney, Australia
Posts: 197
They can be reached on the 601, 602 and 603 engines whichout pulling the manifold off, the last cylinder is had though.

You'll need a stubby 10mm ratchet spanner or 1/4 ratchet for the electrical terminal on the end of the glow plug.

You'll then need a deep 13mm (from memory it's 13mm) and a series of extensions and uni joints (3/8 drive or 1/4 if you've got a snapon set and they'll replace it if you break it ).

It's tricky but managable. Make sure when you tighten the 10mm nut that the cable doesn't turn and touch the manifold and short circuit......been tere, done that

later 4 valve engines 604(never seen one) 605 and 606 engines need the intake manifold to be removed
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Volvo 122S
W201 190D 2.5 manual
W202 C240
W203 C32
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Old 10-21-2004, 10:48 AM
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Thanks, AusMBtech.

I guess I'll give it a try. From the looks of things, I thought for sure the intake manifold would have to come off.

dtimmester
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Old 10-21-2004, 01:11 PM
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Location: Milford, DE
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I've done this job both ways and IMHO it's worth the extra effort to remove the intake manifold. If you decide to try it with the manifold in situ make sure you have plenty of band-aids around because you are going to have at least 8-9 bloody knuckles by the time you are finished. You should also go ahead and remove the noise encapsulation panel under the engine because you are going to drop the sockets/extension 20-30 times- hopefully they won't get stuck between the block and the IP.
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Old 10-22-2004, 08:35 AM
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Join Date: Jul 2004
Location: Sydney, Australia
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If it's a turbo then you must replace the manifold gasket if you decide to remove the manifoldto prevent oil all over the cylinder head.

If it's a non turbo then it's not as important to replace it because there isn't any pressurised oil in the manifold to leak out, although it's still a good idea to replace it

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Volvo 122S
W201 190D 2.5 manual
W202 C240
W203 C32
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