I have a 99' e300 and changing out the glow plugs and almost have the intake. man. out except for 1 screw/bolt, that according to previous post must be removed from the bottom. Is there a trick to this b/c I can't seem to do it or find it? From what I see and feel the bolt connecting the egr to the intercooler pipe, the bolt is not a 10 mm but hollow like an alan wrench screw??? Anyone run into this or have any advice on getting this last screw out?

Thanks
Mitchell

Ok , I removed the bottom protective cover and the screw was a lot easier to get to and it was an allen head type. Now my concern is as I was pulling the plugs off of the glow plugs I crushed one of the plastic housings. The metal insert seems to be fine. Can I just re-attach that and put some silicone sealant to cover up the bare metal that goes around the glow plug as a pig tail, or do I have to do something more drastic.

Thanks Mitchell

I'm sprayed the plugs w/ pb blaster and will attempt extraction tomorrow.

The plastic clips covering the GP can be ordered. Yeah...to get the last IM bolt its easiest to do from below with a couple of long extensions.

Go easy on the GP's. They have a habit of shearing off. The breaking point in destructive analysis that another member did was consistently 80-90nm when held in a vise.

I'd not go more than half that personally......i like the idea of the rat-ta-tat-tat action of an impact wrench if the torque can be dialed in appropriately low enough in addition to firing the engine up and getting it hot first, then using "Freeze" immediately before using the air wrench.

*edit* In addition to 3 consecutive days of application of PB Blaster or sim. As D911 said below, reaming is a must also.

__________________
Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

I would definitely do some reading of the various threads on removing glow plugs in your model of engine. Often they are seized in the threaded area of the Glow Plug to Cylinder Head (when you put them back in use a Never-Seize type compound on the threads), they seize due to Carbon build up gripping the electrode end, or both of them at the same time. Unfortunately the snap off below the hex area of the Glow Plug.

Don't forget to use some method to clean out the carbon build up after the Glow Plugs are removed

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84 300D, 82 Volvo 244Gl Diesel