Biggest performance gain I've found was cleaning the intake and blocking off the EGR and having the intake flap locked wide open. If I re-connect the EGR system my car is noticeably more sluggish.

They're not fast off the line, and there's no point downshifting as it's first-gear start anyway. If you want some slight 'performance' then hold it in 3 to wind up past 2500 rpm- this is where the engine sweet spot starts.

Your car is definitely running cool though, normal running temp should be 80-85.

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1993 320TE M104
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past:

1983 230E W123 M102
1994 E300D S124 OM606 (x2)
1967 250SE W108 M129
1972 280se 3.5 W108 M116
1980 280SE W116 M110
1980 350SE W116 M116
1992 300E W124 M103
1994 E280 W124 M104
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"music and women I cannot but give way to, whatever my business" -Pepys

Alright, finally got some udpate on my glow plugs. Replaced thermostat. No problem. Easyiest thermostat ever. Just Let the coolant drain out before you do it.

Now somehow i turned this into another 606 glow plug thread Maybe i can change the title.

I got 5 out of 6 out! Really did take like 4 hours from time i pulled in garage. the #1 is still stuck in and wouldn't budge with a quarter inch ratchet . I started the job with engine hot and the #1 was stuck so i moved on. They all creaked out slow except one came out easy. Tighten 2 clicks , lossen 3 clicks, tighten 2 clicks , loosen 4 clicks, ... eventually they unscrewed all the way.

3 unscrewed all the way but still wouldn't come out. Two words -- Brake Cleaner! I'd spin with ratchet and wiggle and try to jar em loose, pb blaster em, etc. Then Indy friend told me use brake cleaner so i got a can of the non flammable type. Spray in , spin, spray in threads, wiggle and spin. I used half a can on 3 plugs. Those puppies were out in 5 minutes . So brake cleaner is a great decarbonizer.

Now on to this stuck #1 plug. Wondering best approach. Engine is stone cold. I have a week to wait on my glow plug reamer kit to get here. Here is what i'm thinking -- pull injector one and brake cleaner it from the top. The brake cleaner is non flammable. I think it will evaporate too right? Plus, I will have a week to let it dry out. What do you think?

How do you pull injector anyway? Seems the valve cover has to come off on these. Is it a 27MM like previous generations?

Also, should i heat the plug up with a propane torch ? Could that get it hot enough to help?

Or i could put in other plugs temporarily and start it and let it warm up. Can i run it without intake manifold at all until it warms up?

I'm thinking that brake cleaner from the inside would go a long way to unsticking that sucker but i want to be sure it won't hurt anything. To me it seems if i keep a shop towel in there to catch it from going in combustion chamber, couldn't hurt.

Also if id does break off? Can i just leave it and live with 5 brand new plugs or is there a danger of it falling off in the pre chamber ? 5 out of 6 in Middle Tennessee should start pretty good but i don't want to put wear on other plugs or the engine while it misses.

What is a good maintenance interval on plugs to keep them from getting stuck? Seems a lot of new diesels are getting stuck plugs -- newer MB cdis and VW pumpe deuse have same problem. I ordered the reamer and puller kit here that has reamer and puller for a cdi when they break off. According to tool makers, its easy to remove broken Sealey 3 Piece Glow Plug Puller & Reamer Set SX0406 | eBay I hope one day i get a 2.1 CDI Damn it don't they know americans want a 50 mpg mercedes ?

Anyway, maybe thats why plugs burn out so quick now days? So you don't drive 200,000 miles with them and get them stuck in there!

Thanks for any advice.

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What Would Rudolph Do?
1975 300D, 1975 240D, 1985 300SD, 1997 300D, 2005 E320 , 2006 Toyota Prius

Did you say 1/4" wrench? That must be one strong wrench. My 3/8" barely did the job - barely.

Do not put anything in the injector hole except the injector.

Your reamer/puller may work well, but probably with the engine out and all wiring, fuel lines, and oil filter housing out of the way.

Because the carbon on the tip is the problem, heating the glow plug will probably not do anything.

Try a wrench with a little bit more leverage. Be careful not to pull too hard and snap the glow plug. If you got 5 out, you know what it takes - don't exceed what you think is right. Eventually, you'll hear that chalky dry creak and it will start to come out.

Beru makes glow plug grease for the threads, but that doesn't address the problem of carbon on the tips.

I ordered 6 Berus from Germany just before Thanksgiving. They arrived last week. I've got 6 new in box Bosch glow plugs for the 95 e300d. Send me a pm if interested.

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2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900

Thanks. I already got 6 bosch plugs waiting. How much were your berus?

Yeah , i could budge all the others with the quarter inch craftsmen ratchet. But then i went to the 3/8 with a breaker bar for comfort mainly. Creak, creak is right. I'll give the number one a go. I still wanna see what it looks like in the #1 prechamber. I bet its funky. I can't get my socket on the injector though. Searching now for how to pull injector.

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What Would Rudolph Do?
1975 300D, 1975 240D, 1985 300SD, 1997 300D, 2005 E320 , 2006 Toyota Prius

Berus were $24 each. Injector takes a thin-wall socket readily available online. No need to remove valve cover.

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2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900

Thanks.



Woo hoo. Got that #1 out. Nice warm day yesterday and I went for it. Man brake cleaner really works great. Once you have a few turns out, i started spraying with brake cleaner. The #1 was the hardest and it came out in like 30 minutes. Occasionally i got scared because when I would get a quiet soft budge when loosening instead of the creak, creak , creak, creak of crud breaking loose. When i felt a soft budge that to my paranoid mind felt like soft metal giving in, i immediately when a few creaks tight. Alas, it was ok.

My procedure could be summed up as:
1) Hot engine if you can
2) Brake cleaner on plugs
3) 1 *creak tight, 1 creak loose -- repeat 5 or 10 times
4) 1 creak tight, 2 creaks loose -- repeat
5) Many creaks tight , 3 X many creaks loose as needed. I maxed out at a 3 tight to 12 loose until i could tell i was home free.
6) Brake cleaner every few minutes as you get some room between head and glow plugs. You can see the carbon wash out of hole before the glow plug is all the way unscrewed. Then you know its working.

* You'll know a creak when you hear/feel it. It was about 1/8 inch turn for me i'd guess.

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What Would Rudolph Do?
1975 300D, 1975 240D, 1985 300SD, 1997 300D, 2005 E320 , 2006 Toyota Prius