Do you guys think that putting some Liquid Wrench, or some carbon desolver, into the injector wholes and letting set a day, or more, will make its way to the stuck glow plugs?

(And of course, after I get it runnning again I will change the oil immediatly! Bummer is, I just changed it before I started this job!

Absolutely - Maxbumpo is right. #3 GP on the OM606 in the E300 we have was a PITA to remove. It would turn out a few turns and then stiffen up. Turning out any more and the GP would pop and bind, so I stopped right there. I already had the injectors out for service, so I squirted some PB Blaster down into the pre-chamber and let it sit for a day. The GP came out much easier after that - no more popping and the bind was greatly reduced.

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- Greg -
1973 220D, The Prodigal Benz
1974 240D

Today is 1/26/17; back on the 21st, as recomended, I removed the fuel injectors over the two stuck glow plugs. (The car is in the garage where I can keep it warm.) After a couple days I tried using easy-outs (screw removers) of various sizes; the first GP I worked on was the back one, #6. At first I thought it was working but then is was able to see the the GP was NOT turning. I worked on GP 1 for a while; all I am getting is either jammed easy-outs, or ones that turn and create a whole bunch of metal shavings. I am hoping it's the plugs that are being eaten away and not the head. (I did not use a drill that is larger in diameter than the GP.)

One guy I talked with, at a tool specialty shop, recomended I use JB Weld to glue a bolt into the wholes I drilled; let it harden for a day or two and then use a slide hammer to jerk (what remains of) the plugs out.

When I drilled I used a larger bit to drill the first few mm (about as deep as the threaded portion.) Then I used a much smaller bit to drill in about the lenght of the GP, just before the smaller portion begins.

So, I'm thinking if the JB Weld was only at the deeper part, and held strong, this technique might work.

What do you guys think?

I have studied drilling out the glow plugs, but it looked so intimidating I let the dealer change them. Fortunately they did not break any.

I am sure that if you break that easy out you will be in big trouble. As I understand the procedure, you drill through the threaded portion with a bit larger than the plug body but smaller than the threads, so the threads can be picked out later. You then drill into the plug and thread the hole carefully so you can pull the plug with a slide hammer. It is not clear to me if you drilled through the threaded portion of the plug with a size that the plug body can slide through. It sounds like the small hole you drilled just needs to be tapped so you can slide hammer it out. Be careful to not break the tap. J B Weld is great but it will not do what you want it to. You have to drill through the threaded portion with a bit large enough to drag the plug body through the hole. Then you can use a slide hammer to pull the plug straight out using a bolt threaded into the smaller hole in the body.

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'97 E 300 D

Wow, you're in a tight spot there. I think you should consider taking the car to a shop that has the special tool kit for removing the broken glow plugs. You've got all the stuff out of the way (I think) so it should be pretty straightforward for them, unless the holes you've drilled are an issue.

2nd worst case, head comes off and goes to a machine shop.

Worst case, you have to shop for a new (maybe used) head.

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Respectfully,
/s/
M. Dillon
'87 124.193 (300TD) "White Whale", ~392k miles, 3.5l IP fitted
'95 124.131 (E300) "Sapphire", 380k miles
'73 Balboa 20 "Sanctification"
Charleston SC

Thanks buddy (Dillion?)

I became good friends with a Mercedes mechanic (Mark Barker) back in Lynchburg, VA; the guy had his own shop and was like a magician when it came to diagnosing and repairing Mercedes; for more than 30 years, he had been to all the Mercedes training courses; he specialized in them. (All I drive are older "owned" Mercedes; presently, 85 300TD and 99 E300 TD.) Unfortunately, I moved to Klamath Falls, OR, April 2016, because my wife took a good job here. (I am retired and enjoy working on these old cars.)

There is not a single mechanic that knows anything about Mercedes, especially diesels (at least none that I've found) here in this small farm community!

In addition to this forum; I messaged my old mechanic, Mark, yesterday. (I should have communicated with him, in detail, from the beginning of this project!) What he told me was to buy this tool B900-0199 Broken Glow Plug Removal Tool - Wise Auto Tools.

It's a bit pricey for my budget but much cheaper than the alternatives. So, I'm going to get the tool set and may need the tools to straighten out the threads on #1. (I did a lot less drilling on #6) I am confident that this will be the end of the problems.

Apparently, anyone who has broken or seized glow plugs should save themselves A LOT of headaches and troubles; just buy one of these tool sets first!

It may be a few weeks before I get my hands on the tools, but I will definitely keep you posted!

Yesterday, I was warned by a Benz expert to stay away from the JB Weld idea!

Plus, I've had a very difficult time getting any taps to work well enough to hold bolts tightly.

Friend, that 'Glow Plug Removal Tool' is just the drills and taps mentioned in the glow plug removal link you posted earlier, with a ratcheting tap wrench, just practice tapping holes properly and do it yourself.


Perhaps use a bolt with washers / socket underneath to 'drift' out the broken glowplug rather than a slide hammer as if the thread you've cut is not good then the slide hammer will just rip it out

Thanks, a lot, Hario, for the encouragement! I could see that I already have some of the parts in these kits; plus, I am reluctant to fork out the amount of money they want.

I do need practice tapping; the tap bit tool I have now has a very short handle, and I don't have any sockets that will fit the tap bits. I am going to a tool shop later this week. From what the locals tell me, is that this tool shop has the biggest supply of the kinds of tools I need.

After I get some new tools, I will take your advice and hope things go well! I am a very persistant person, tenacious at times.

Thanks again, Hario; I appreacite all the input I get here!

I followed this procedure by the way! (his funny accent is northen English..) lol


https://youtu.be/U9AO_cDdwS8

Will this help? https://www.amazon.com/broken-glow-plug-removal-tool/s?ie=UTF8&page=1&rh=i%3Aaps%2Ck%3Abroken%20glow%20plug%20removal%20tool

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85SD 240K & stopped counting painted, putting bac together. 84SD 180,000. sold to a neighbor and member here but I forget his handle. The 84 is much improved from when I had it. 85TD beginning to repair to DD status. Lots of stuff to do.