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Old 06-20-2020, 03:29 PM
ROLLGUY's Avatar
ROLLGUY
 
Join Date: Oct 2007
Posts: 7,260
CDI glow plug replacement- Buckle up, your'e in for a fun ride!

My niece owns the CDI that got me introduced to the W211 platform years ago. I bought the car from a dealer in Ohio for cheap (at the time) because it had the "Black Death". I repaired it (thread here somewhere), but there was also a broken glow plug causing a CEL. I got the CEL to go out by faking out the computer with the installation of a glow plug screwed into a nut welded on a tube, and bolted to the intake manifold. That satisfied the system for years, until January when another glow plug went bad. I decided to just replace them all, and deal with whatever it took to get them out. She ordered the parts, and then the COVID-19 thing prevented her from getting the job done until this week. She had a week off, so she scheduled the job.

I ordered a broken plug removal kit CDI broken glow plug removal tool- how does it work? and watched a few videos.

Ready or not, here we go!
I first removed the covers, and then the fuel rail. I did not remove any of return hoses, there was enough slack to get the rail out of the way. I covered all the fuel nipples with tape, and later with some caps when the tape came off. Of the six plugs, one needed the complete treatment using most of the tools in the kit. One came completely out without issue, the other four came out from the threads, but were stuck with carbon on the shaft.
With the four plugs out as far as possible, I filled the wells (area around the glow plugs) with PB Blaster. I applied more a couple times while I worked on other plugs.

The photos may be a little mixed up, but the entire job will be explained, even if the explanation does not match the photos.
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