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  #136  
Old 03-01-2008, 01:59 PM
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"Probably one of my happiest DIY moments ever

I have lost A LOT of hair over the past 12 hours"

Welcome to the club.........When I got the last plug out, you would have thought I won the lotto!! Great job on your part, and thanks for providing pictures.

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  #137  
Old 03-01-2008, 02:06 PM
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My pleasure. I'm still new to this board and not sure what the etiquette is here; I didn't want to "hijack" this thread, but didn't want to start one that would be considered redundant either. If I'm not approaching this right just lemme know.

FWIW I used a 9/32 bit (worked up from 11/64) and threaded it with a 5/16 tap.

If anyone attempts this, I'd say the biggest concern is keeping the bit pointed in the right direction. Stop frequently to make sure things look right.

I'da been pooched if it wasn't for this forum. I can't thank you guys enough.

One thing I can guarantee: That IM is coming off every fall, and thr GPs will be pulled so I can ream those holes. Never going through this BS again.
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1999 e300d PlantDrive WVO/SVO conversion
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Last edited by notfarnow; 03-01-2008 at 02:48 PM.
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  #138  
Old 03-01-2008, 04:35 PM
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Congratulations! You almost made that seem routine. The drilling out of the old threaded section scares the crap out of me. I also wonder what you do if the threading operation breaks the old glow plug remnants loose.

Congratulations again! Well done. Jim
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1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)
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  #139  
Old 03-01-2008, 05:37 PM
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What is the record time?

From busting to removing?

Wow, welcome to the forum and the 606, everything about them is easier than what you just did!

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1999 E300DT Obsydian Black Metallic, Heated Full Leather Parchment options, E2, K2, 136,000+, best 36.5 mpg - GP's 12-04 & 11-12 Zero Stuck
2010 Honda Odyssey - The BrideMobile - best 26.5
(2) 2005 Honday Accord- (1 -Corporate 1 - Personal) - 110,000 4-cyl 30mpg
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  #140  
Old 03-01-2008, 06:50 PM
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Ha! Thanks. I hope that's as bad as it gets!

There was no way I was bolting it back together with one dead plug. Might be fine where you guys live, but in our climate I really can't get away with it. I've been starting on 5 plugs for a week and couldn't stand the smoke & roughness. I love this car... I didn't buy a nice Benz to have it running like that.

Back to the garage... I've got fuel lines to replumb now.
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1999 e300d PlantDrive WVO/SVO conversion
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1990 Toyota 4Runner FrankenDiesel swap
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  #141  
Old 03-01-2008, 06:59 PM
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I've always wondered if the plug broke after the threads were unscrewed could you "eject" it by simply running the engine? It might shoot out like a bullet but I wonder if you simply tried to cover the hole with something to catch it could you just use the compression of the engine to pop it out? Might be worth a try before drilling...just throwing it out there and hope I never have to find out!
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  #142  
Old 03-01-2008, 07:08 PM
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yeah I wondered that too, but once I set up the puller I was surprised how much force it was taking before it even started to move. I was very concerned that the tapped threads wouldn't hold.

In fact, I was so concerned that I went back, cut the taper of the tip of the tap and re-tapped it. That allowed me to get some sturdy threads a little bit further down. That gave me a couple extra turns on the threaded rod... I think it was worth sacrificing my tap for that.

Speaking of sacrifices, I'll have to think of an appropriate sacrifice to the om606 gods. My power sunroof mysteriously started working too, so I've got to appease them, lest they frown upon me.
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1999 e300d PlantDrive WVO/SVO conversion
**note to self: oil changed at 268k kms**
1990 Toyota 4Runner FrankenDiesel swap
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  #143  
Old 03-01-2008, 07:56 PM
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Quote:
Originally Posted by notfarnow View Post
The one that broke was a Beru with the mercedes benz logo on it. According to the records that came with the car, they were changed at the dealership by the PO 2 years ago.
Yikes - you mean the last set only lasted 2 years? How many miles was that? On a side note, someone else with a 606 had a similar problem (short plug life), and was trying to figure out why. He had his injectors tested and found that the spray patterns were poor, which may have caused carbon buildup, which could reduce plug life significantly. You might want to have your injectors looked at, or you could end up going through this whole procedure again in 2 years...

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  #144  
Old 03-01-2008, 09:12 PM
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Quote:
Originally Posted by gsxr View Post
Yikes - you mean the last set only lasted 2 years? How many miles was that? On a side note, someone else with a 606 had a similar problem (short plug life), and was trying to figure out why. He had his injectors tested and found that the spray patterns were poor, which may have caused carbon buildup, which could reduce plug life significantly. You might want to have your injectors looked at, or you could end up going through this whole procedure again in 2 years...


Only one plug was bad, but I decided to engage in a pre-emptive attack against all of them. Glad I did... the back 3 were all really carboned up and hard to move. Hate to think what they would have been like in another year.

I changed 'em all, but from now on I'll take them all out once a year to ream the holes, and put them right back in.

Good tip on the injectors. Maybe I'll buy a spare set and get a pop tester.
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1999 e300d PlantDrive WVO/SVO conversion
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1990 Toyota 4Runner FrankenDiesel swap
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  #145  
Old 03-01-2008, 10:18 PM
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Hopefully you reamed out the holes too before you put the new ones in!
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  #146  
Old 03-01-2008, 10:46 PM
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Originally Posted by nhdoc View Post
Hopefully you reamed out the holes too before you put the new ones in!
Nope, just threw 'em back in using my impact gun set on high.


kidding

yep, I got the om606 GP reamer from diesel911, the first or second day he had them up for sale. Pretty slick rig. His next project should be a jig for drilling out GP when the bust off!
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1999 e300d PlantDrive WVO/SVO conversion
**note to self: oil changed at 268k kms**
1990 Toyota 4Runner FrankenDiesel swap
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  #147  
Old 03-18-2008, 12:25 PM
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Lightman great post I`m changing the fuel line to the shutoff valve ? It runs down from the fuel filter housing and the hose has a brass o shaped ring attached with a banjo bolt? My question is do the bolts on the intake have to be torqued if yes I`ll have to borrow one I guess. thanks for info
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  #148  
Old 03-18-2008, 01:37 PM
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Everything should be torqued...
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  #149  
Old 03-18-2008, 03:04 PM
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Quote:
Originally Posted by skydog View Post
Lightman great post I`m changing the fuel line to the shutoff valve ? It runs down from the fuel filter housing and the hose has a brass o shaped ring attached with a banjo bolt? My question is do the bolts on the intake have to be torqued if yes I`ll have to borrow one I guess. thanks for info
The SOV is the black plastic valve on the opposite side of the IP. You are changing the "check" valve. The check valve is intergral to the banjo bolt. Don't know its torque.

The IM cap bolt torque is 20NewtonMeters. You torque from the center, working outwards. You'll need a new IM gasket and should get a new EGR "seal" ring too while its apart.
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  #150  
Old 03-18-2008, 05:34 PM
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Quote:
Originally Posted by notfarnow View Post
yep, I got the om606 GP reamer from diesel911, the first or second day he had them up for sale.
Where does he sell it at? Is it any different from the one that baum tools sells?

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