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  #1  
Old 08-23-2020, 06:48 PM
JimP
 
Join Date: Jun 2011
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HELP! WTF is this? '95 E300D glow plug removal

Hi everyone! A lot of swearing and gnashing of teeth the last few Sundays as I wrestle with removing stuck glow plugs from my 1995 E300D OM606.910. One plug left and I can't get to it. What is this round vent device on top of the injection pump that is in my way and can it be removed safely? I loosened and unscrewed it but it will not pull out. The MB engine manual describes it as an atmospheric device but does not detail how it is attached to the car. Any and all advice greatly appreciated.

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HELP! WTF is this? '95 E300D glow plug removal-img_0133.jpg  
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  #2  
Old 08-23-2020, 10:23 PM
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Quote:
Originally Posted by jtpoltrock View Post
... What is this round vent device on top of the injection pump that is in my way and can it be removed safely?...
Altitude compensator.

I wouldn't mess with it
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  #3  
Old 08-23-2020, 10:46 PM
Rogviler's Avatar
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Join Date: Apr 2011
Location: Colorado
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To hopefully be more helpful... You can't remove it that way, it takes much more digging and isn't going to be worth it. Instead, you're better off marking your timing and then loosening and rotating the IP away from the engine. Or perhaps there is a tool you can get or make that would be able to get in there? It's hard to tell what angles you're working with from a single picture, you'll have to do some figuring and supposing if you want to go that way.
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  #4  
Old 08-23-2020, 11:23 PM
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When you re-install the Glow Plugs be sure to use some never-seize type compound on the threads of the Glow Plug so they won't be stuck again.
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  #5  
Old 08-23-2020, 11:52 PM
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In the attached picture there bent obstruction wrenches that are S shaped and sort of U shaped. There is other shapes but those are the most common shapes.

Some people like to use gear wrenches (a combination wrench with a ratcheting box end) on the Glow Plugs. Some gear wrenches are flat and others are angled.
In particular the gear wrenches with both ends having the ratcheting box end are angled.
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HELP! WTF is this? '95 E300D glow plug removal-s-shaped-obstruction-wrenches-2020.jpg  
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  #6  
Old 08-24-2020, 09:02 PM
JimP
 
Join Date: Jun 2011
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Thanks for all of the advice. You might be able to see that the glow plug behind the atmospheric compensator is snapped off at the head. I want to try and remove it with a long EZ OUT and an impact on low air setting (that is how I successfully removed 3 of the other broke plugs). If a manual attempt is made a short EZ OUT has to be used due to the limited clearance, and that is ripping the metal on the threaded portion of the plug to shreds. I will tighten the atmospheric compensator down and leave that lie. I took the intake off to replace the leaking fuel lines and injection pump and thought, "while I'm here I might as well replace the glow plugs". Sheesh, what a pain in the ass this has become and I haven't even started on the fuel lines or the IP! Anyway, thanks for all the suggestions and help.
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  #7  
Old 08-26-2020, 12:52 PM
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Quote:
Originally Posted by jtpoltrock View Post
Thanks for all of the advice. You might be able to see that the glow plug behind the atmospheric compensator is snapped off at the head. I want to try and remove it with a long EZ OUT and an impact on low air setting (that is how I successfully removed 3 of the other broke plugs). If a manual attempt is made a short EZ Out has to be used due to the limited clearance, and that is ripping the metal on the threaded portion of the plug to shreds. I will tighten the atmospheric compensator down and leave that lie. I took the intake off to replace the leaking fuel lines and injection pump and thought, "while I'm here I might as well replace the glow plugs". Sheesh, what a pain in the ass this has become and I haven't even started on the fuel lines or the IP! Anyway, thanks for all the suggestions and help.
Remove the Fuel Injection Pump before starting on that last Glow Plug.

You have already had much better then average luck removing the broken glow plugs.
When you get a chance post a picture and the size of the Ez-out you used so we can see what type it is and the size if the drill bit if you used one and the company that made the Ez-out. That because there is many types of Ez-outs and companies that make them.

Some Ez-outs work better then others for particular jobs and the size used is important as well as using the right sized drill if you drill.

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  #8  
Old 08-26-2020, 01:53 PM
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240D.Bill
 
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IP timing

Quote:
Originally Posted by jtpoltrock View Post
Thanks for all of the advice. You might be able to see that the glow plug behind the atmospheric compensator is snapped off at the head. I want to try and remove it with a long EZ OUT and an impact on low air setting (that is how I successfully removed 3 of the other broke plugs). If a manual attempt is made a short EZ OUT has to be used due to the limited clearance, and that is ripping the metal on the threaded portion of the plug to shreds. I will tighten the atmospheric compensator down and leave that lie. I took the intake off to replace the leaking fuel lines and injection pump and thought, "while I'm here I might as well replace the glow plugs". Sheesh, what a pain in the ass this has become and I haven't even started on the fuel lines or the IP! Anyway, thanks for all the suggestions and help.
Rotating or removing that pump altogether may save you a lot of trouble. That is if you are comfortable with re-timing the pump. Marking the pump’s current setting doesn’t help if the pump is already slightly off the mark.
If you don’t know how already, I highly recommend learning how to set the timing on your pump if you don’t already. It’s super easy and if it hasn’t been done in awhile or is out of sync you’ll notice a huge difference in power, fuel mpg, lower smoke, and it’s a recommended tune up item.
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  #9  
Old 08-26-2020, 04:28 PM
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Quote:
Originally Posted by Diesel911 View Post
Remove the Fuel Injection Pump before starting on that last Glow Plug.

You have already had much better then average luck removing the broken glow plugs.
When you get a chance post a picture and the size of the Ez-out you used so we can see what type it is and the size if the drill bit if you used one and the company that made the Ez-out. That because there is many types of Ez-outs and companies that make them.

Some Ez-outs work better then others for particular jobs and the size used is important as well as using the right sized drill if you drill.
I second the motion! If you've found a particulary well suited EZ-Out for these glow plugs, please share this info and you will have eternal gratitude from many people on this forum... and some good Karma points too!
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Current rolling stock:
2001 E55 183,000+ Newest member of the fleet.
2002 E320 83,000 - The "cream-puff"!
1992 500E 217,000+
1995 E300D 412,000+
1998 E300D 155,000+
2001 E320 227,000+
2001 E320 Wagon, 177,000+

Prior MBZ’s:
1952 220 Cab A
1966 300SE
1971 280SE
1973 350SLC (euro)
1980 450SLC
1980 450SLC (#2)
1978 450SLC 5.0
1984 300D ~243,000 & fondly remembered
1993 500E - sorely missed.
1975 VW Scirocco w/ slightly de-tuned Super-Vee engine - Sold after 30+ years.
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  #10  
Old 11-16-2020, 08:15 AM
JimP
 
Join Date: Jun 2011
Posts: 3
Sorry I haven't posted my updates lately. I live in Kenosha, Wisconsin and after the rioting here in late August I have not worked much on the Mercedes glow plug debacle. Yesterday I was back at it, all enthusiastic and energized to get this part of the job done. I had a cobalt EZ Out with a large nut tig welded on the head on hand. EZ went in and electric impact with a universal(to get around that round altitude compensator) commenced. Gradually increased the torque...did not budge. Out comes the air impact, starting on its lowest setting working up. No go after 10-15 minutes of that. Out comes a large socket and a manual attempt. It did not take long before "SNAP" went the EZ Out, flush with the head. F**K!! I finished my cigar and went inside for supper.

Again I have to ask this group, can that atmospheric compensator be removed? if that damn thing was not in the way I know the plug would be out by now.

I am NOT going to remove the head. Just ain't gonna do it.

What are everybody's thought on running with 5 glow plugs?

If you have any other suggestions, please share. I am starting to have really negative feelings about the car, which I once love. Thanks.
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  #11  
Old 11-17-2020, 02:33 PM
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Running on five glow plugs is fine. I did it for about a year and a half on 98 E300 until I had to pass inspection. This is in New England so it gets pretty cold.
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  #12  
Old 11-17-2020, 08:25 PM
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Whenever you are using an ezout or a tap, using a larger tool is never an option. Bad times will follow

Its also a great idea to start the engine and get it upto normal temperature so cylinder head will leave its deathly grip on the glow plug.
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  #13  
Old 11-17-2020, 08:55 PM
Diesel911's Avatar
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Quote:
Originally Posted by jtpoltrock View Post
Sorry I haven't posted my updates lately. I live in Kenosha, Wisconsin and after the rioting here in late August I have not worked much on the Mercedes glow plug debacle. Yesterday I was back at it, all enthusiastic and energized to get this part of the job done. I had a cobalt EZ Out with a large nut tig welded on the head on hand. EZ went in and electric impact with a universal(to get around that round altitude compensator) commenced. Gradually increased the torque...did not budge. Out comes the air impact, starting on its lowest setting working up. No go after 10-15 minutes of that. Out comes a large socket and a manual attempt. It did not take long before "SNAP" went the EZ Out, flush with the head. F**K!! I finished my cigar and went inside for supper.

Again I have to ask this group, can that atmospheric compensator be removed? if that damn thing was not in the way I know the plug would be out by now.

I am NOT going to remove the head. Just ain't gonna do it.

What are everybody's thought on running with 5 glow plugs?

If you have any other suggestions, please share. I am starting to have really negative feelings about the car, which I once love. Thanks.
I know the altitude compensator can be removed from my year and model. It can likely be removed from yours. I have not paid attention to the thread of that sort of stuff.
So hopefully someone will post who has done it.

Broken Bolt Extractors like the ones in the picture can sometimes expand what you are trying to get out.
My opinion using an impact wrench was not a good idea.

That being said can you get the broken Blot extractor out? The are often so hard you cannot drill them out easily.

There is a kit and some members on this forum have used a kit but I don't know if it is the same kit.
https://www.benzworld.org/threads/looking-for-broken-glow-plug-removal-kit.3061774/#post-18097254

There are places you can take your car and they have a machine that has a cooled electrode and they burn out what is broken and chase the threads. They can burn through a broken Bolt Extractor.
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HELP! WTF is this? '95 E300D glow plug removal-broken-bolt-extractor-spiral-flute.jpg  
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  #14  
Old 11-17-2020, 08:59 PM
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You might explain the situation to a Bosch fuel injection shop and they might give an idea about removing the altitude compensator.

You might mark the flange and block where the fuel injection pump mates (so you can return it to where you had it) and maybe you will be able to tilt the Fuel Injection Pump and get a little more room.
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Last edited by Diesel911; 11-18-2020 at 11:55 PM.
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  #15  
Old 11-17-2020, 10:06 PM
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I have a 92 with a mw pump when I removed mine just under the capsule was 2 large nuts I put wrenches on and it twisted off. But mine was a turbo your is na so could be different.

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