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Old 11-25-2014, 12:30 AM
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Glow plug replacement....is each generation of engine worse then the last?

With every generation of Mercedes diesel engines; does replacing the glow plugs get harder and harder?


Doing the glow plugs on my 617 was fiddly at times but overall straightforward and simple. I would imagine that a 616 is even easier. My 603? A complete pain in the rear and I suspect a 602 isn't much different. I've also read plenty of threads about 606 glow plugs breaking and causing a total nightmare. If the trend continued I can only imagine what the job is like on engines made in the last ten years....

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Old 11-25-2014, 01:41 AM
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It's not bad. I've had all the engines pre-00 and they're all straight forward. OM60X engines are all basically the same. One just risks breaking a glow plug body in the head if they haven't been reasonably maintained (excessive carbon build up, removing plugs on a cold engine, etc).

Just more stuff to get in the way is all. For me it makes a good reason to get some preventive maintenance done.
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Old 11-25-2014, 08:02 AM
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The 60x heads are a crossflow design, better for performance and economy.

The downside is what you've found out, more difficult to get to some items.

Use quality glow plugs and ream out the holes.
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Old 11-25-2014, 12:55 PM
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You should try the later OM611/612/613 CDI engines. They shear off pretty much 50% of the time. Thankfully they still start with all of them gone! I have one stuck in my OM611 now, I'm just going to leave it.

I imagine the later (OM648 etc) engines are even worse.
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Old 11-25-2014, 05:15 PM
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I just did mine on the 300TD, the glow plugs themselves were easy to get out, ream and install. It was the install of the intake manifold, socket wrench gynmastics to tighten up the 12 bolts, fussing with the GP wire loom, getting all the injection lines clipped back in ohh and of course replacing the return lines(might as well right )because guess what I managed to break one. All in all, I got what I bargained for and then a bit more.
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Old 11-25-2014, 06:02 PM
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I went thru all that this summer on my 603. Remove intake and other stuff, ream the holes, new plugs, clean intake, etc. But I'm glad I did. It's only dipped into the upper 20's so far but it starts quick and runs smoother when cold than it has since I've owned it. It was way past overdue.
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Old 11-26-2014, 12:48 PM
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Quote:
Originally Posted by Fulcrum525 View Post
With every generation of Mercedes diesel engines; does replacing the glow plugs get harder and harder?


Doing the glow plugs on my 617 was fiddly at times but overall straightforward and simple. I would imagine that a 616 is even easier. My 603? A complete pain in the rear and I suspect a 602 isn't much different. I've also read plenty of threads about 606 glow plugs breaking and causing a total nightmare. If the trend continued I can only imagine what the job is like on engines made in the last ten years....

617 GP's are pretty easy, but depending on the cylinder, can't use a socket...so therefore can't use a torque wrench.

606 is a bit more difficult...but remember...warm engine, lots of PB Blaster, don't exceed 40Nm of off-torque. If it doesn't pop by 40Nm, add PB blaster, go inside and have a refreshment while you wait. Repeat.

The 648 is much easier than 606. I've only changed one GP on the 648 in the last 109,000 miles, but employed the tried-and-true 606 removal technique above.
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Old 11-26-2014, 01:45 PM
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This thread reminds me of the trouble I had getting #5 GP out of my 617. It unthreaded but I couldn't manage to get the plug the rest of the way out. It was swelled at the tip. Since I had 1-4 done and I was getting pissy in the cold weather, I had an idea. Fire up the engine and let the cylinder pressure shoot it out. Well, it worked! The cops on the other side of the parking lot were not too impressed as they were responding to a domestic dispute. The sound of what a .45ACP makes across the parking lot left a few stains in their drawers, I imagine. I never did find that glow plug...

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