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  #1  
Old 01-26-2007, 04:53 AM
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Glow Plug replacement OM603

Here's the situation:

First, preglow indicator light stopped coming on regularly two days ago. It has come on twice since. I checked the relay and it appears fine.

I spent most of the evening working to get the six old GPs out. The first two GPs' nut that holds the wire on the GP will not come off. In attempting to do so with various lubricants, the nut finally broke off the core from the inside of the GP, and both came out with the top nut and wire securely attached.

The third has a non-OEM nut and wire configuration in which the nut/wire is one piece and not 10mm. A typical socket isn't going to get the wire off (1/4" Gator socket might work?). I should mention that I'm attempting to remove and then replace the GPs without removing the intake (1/4" sockets, excessive extentions, and u-joint).

So the fourth GP came out as they all should have, the fifth nut and wire came off fine but I can't get a socket in all the way to get the actual GP out, and at the 6th GP I called it a night.

I see three options, and I would appreciate advice on any or all of them.

1) Remove the intake.
Will I need any special tools?

2) Sockets and patience
I can get the new GPs in fine, but trouble with getting wire back on. Again, socket/wrench accessibility issues. Suggestions?
Replace nuts and wire. Can I get OEM nuts fairly easily?

3) Take it to a shop...
Estimate?

The car is a 1987 300D OM603, first Mercedes I've ever owned. Any help would be greatly appreciated. I desperately need to have this car running in as few days as possible. Thanks again.

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  #2  
Old 01-26-2007, 09:02 AM
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Try this thread. It was titled tools for pulling intake on 603. Most people do pull the intake to replace glow plugs.
Tools for pulling intake on 603
good luck
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  #3  
Old 01-26-2007, 11:50 AM
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If you're having trouble with the rear glow plugs, keep the intake manifold in place but remove the cruise control actuator. It's held by four bolts into the block, a couple of electrical connectors and three throttle rods.

If you remove the intake manifold, first release the injector lines at both ends then use all varieties of 6mm het bix tools you have. Good time to check and correct bad injector line clamps.

Sixto
93 300SD 3.0
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  #4  
Old 01-26-2007, 12:02 PM
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Remove the cruise servo, makes the job a snap. Pulling the intake would be further down my list now that I know how much room the servo makes.
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I'm not a doctor, but I'll have a look.

'85 300SD 245k
'87 300SDL 251k
'90 300SEL 326k

Six others from BMW, GM, and Ford.

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  #5  
Old 01-26-2007, 12:12 PM
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I'm planning on doing it the "long way" by removing the intake. I already bought a new set of injector line clips (some are already broken) and I'm going to do the EGR delete while I'm in there and also clean out the intake as well as I can.

I could only get to the first 3 GPs with the intake in-place, but never removed the cruise servo like hitman suggested (I heard his suggestion after the fact).
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  #6  
Old 01-26-2007, 12:14 PM
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I'd take the intake to a machine shop to hot tank it, it's FULL of crap.

Also, all the new GPs from Bosch are the Duraterm ones. This means you can do the extended glow mod later
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I'm not a doctor, but I'll have a look.

'85 300SD 245k
'87 300SDL 251k
'90 300SEL 326k

Six others from BMW, GM, and Ford.

Liberty will not descend to a people; a people must raise themselves to liberty.
[/IMG]
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  #7  
Old 01-26-2007, 12:29 PM
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did we ever find out how you got into your car hitman?????????
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commercial fisherman diesel in my blood in my boats trucks and Dear old Dad has had me drivin them since i got my first license in 1968
1986 300 SDL 427654
1999 Chevy Crew Cab Dually 225423
1986 300 SDL 287000 Dad's
1987 190 Turbo 158000 Mom's (my inheritance)
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  #8  
Old 01-26-2007, 12:30 PM
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I LOVE BRUNETTES
 
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Quote:
Originally Posted by captainmonk View Post
did we ever find out how you got into your car hitman?????????


Sunroof, haven't had a chance to mess with it. At least it is secure
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I'm not a doctor, but I'll have a look.

'85 300SD 245k
'87 300SDL 251k
'90 300SEL 326k

Six others from BMW, GM, and Ford.

Liberty will not descend to a people; a people must raise themselves to liberty.
[/IMG]
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  #9  
Old 07-20-2008, 10:16 PM
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Thanks to all the info. The cruise servo was definitely a good call.
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  #10  
Old 07-20-2008, 11:40 PM
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Don't forget to ream/clean the carbon out of the Glow Plug holes and put some Never-Seeze type compound on the threads of the new ones when you install them.

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84 300D, 82 Volvo 244Gl Diesel
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