Got bad #5 glow plug on my wifes 96 E300D (Non-Turbo). At Her request it will be sold in spring so I'm planning on only replacing the bad one. Has anyone replaced #5 by removing only the crossover or upper intake plenum? Sprayed some Blaster on the culprit and it looks like it may be doable with the bottom intake in place. Thanks.

Pretty certain I have changed no. 5 before with just the crossover pipe off, I think there's just enough room to get a 1/4" ratchet in there.

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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

I would do it with the engine hot at least. Some have started it loosening initially with the engine running but you have to take reasonable precautions like safety glasses or I would ... I hope your plug comes out easy.

Somewhere in the DIY there is suggestions on how to attempt not breaking them and repair if one does break off.

DIY Repair Links
DIY Links by Parts Category - PeachParts Mercedes ShopForum

PeachPartsWiki: Do It Yourself Articles - Mercedes Vehicles

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84 300D, 82 Volvo 244Gl Diesel

I have changed #3 without removing the manifold and would probably try #4, but for any others I would remove it.

In my experience R & R 'ing the manifold is less trouble then trying to work around it. It takes 10 minutes.

You do need a long reach 40torx socket to avoid breaking the CCV fittings from the manifold.

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Greg
2012 S350 BlueTEC 4Matic
2007 ML 320 CDI
2007 Leisure Travel Serenity
2006 Sprinter 432k
2005 E320 CDI
1998 SLK230 (teal)
1998 SLK230 (silver)
1996 E300D 99k, 30k on WVO
Previous:
1983 240D, on WVO
1982 300D, on WVO
1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix
1983 380 SEC w/603 diesel, 8k on WVO
1996 E300D 351k, 177k on WVO

Thanks to all who responded, I will just pull the intake to be safe.

A good opportunity to clean the manifold, remove all the carbon, make sure the crankcase breather pipes are OK. Once you have the manifold clean you can defeat the EGR valve and it will stay clean.

Jeremy

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

As Jeremy said - good idea to clean up the manifold now, get a big extreme duty red trash bag and about a couple of gallons of B100 biodiesel - remove the vacuum flappers - breather plastics etc. and put in the bag and fill with diesel. leave it be for 6 or 8 hours. drain out into old oil bottles - pressure wash the nasty manifold at a car wash that allows engine cleanup - the blackness would be evil.

But the upside is that the engine will breathe really nice - like it should.

I have got manifold removal down to a timed 10 minutes now - with a makita small impact. - the joys of owning an OM606.

anyway - remove the plug with the engine blazing hot - it has the least amount of breaking chance.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

My mistake was removing the glow plugs when the engine was cold. Now my #4 & #5 are broken. Going to attempt to remove those this weekend... Wish me luck! To make things worst all of the ones that I was able to unscrew are swollen, too.

it is always wise to get a split nut glow plug puller set from Amazon - the broken ones are a real pain to get out - careful aiming with a drill can save you and use of an old gutted glow plug as a guide for the heating element puller is also crucial.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

So...

the B100 will eat the EGR gunk, but will not eat a trash bag?

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

The red thick trash bags are pretty stout, I have put some B100 in it along with some parts in it for 4 or 5 hours and it did not eat it away.

btw - I got these from work - I was told they are called hazmat contractor trash bags.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)