Replacing GPs is a *****!!! HELP! OM601

[190D22]

What is the trick to getting the GPs out on a 601?!?! The tech at the dealership says "you need to be a contortion artist" to get them out with out pulling the intake manifold. I am having most trouble with GPs 1 and 3.

[DieselAddict]

I'm not familiar with the 601's but why are you afraid of pulling out the intake manifold? I've heard of people changing glow plugs without taking off the intake manifold on a 603 engine, and I think they're crazy. I always prefer to take the extra time to get the proper access that I need to do the job properly and comfortably rather than trying to save time by twisting my bones and scraping my flesh which may actually make the job take longer to complete.

[Johnhef]

and make your engine happy by cleaning out the intake while its off.

[Brian Carlton]

Originally Posted by Johnhef

and make your engine happy by cleaning out the intake while its off.

What is the actual time to pull the intake on the 603? Is this a one hour job?
It doesn't seem like it has too many fasteners?

[190D22]

Mine would be a mess to take off... There's fuel lines, vacuum lines, and throttle linkage all attached to the manifold. I don't want to take all that extra work to get the GPs out.

BUT I have found a good way to get them out I believe. I will know for sure today if it works or not, but all you need is some extensions then a flexible attachment on the end of a ratchet.

[DieselAddict]

Brian, you should be able to remove the intake on a 603 engine and put it back within an hour if you have the right tools. Basically all you need is a 6 mm hex-bit socket, an extension and a universal joint. You'll also need a 10 mm socket to remove some of the stuff that's attached to the manifold. The crossover pipe is easily removed with a 5 mm hex key.

190D22, let us know how it went.

[Brian Carlton]

Originally Posted by DieselAddict

Brian, you should be able to remove the intake on a 603 engine and put it back within an hour if you have the right tools. Basically all you need is a 6 mm hex-bit socket, an extension and a universal joint. You'll also need a 10 mm socket to remove some of the stuff that's attached to the manifold. The crossover pipe is easily removed with a 5 mm hex key.

Thanks, it didn't seem like a big deal. I'm sure you could spend much more time trying to get to all the glow plugs with the manifold in place.

[Johnhef]

Yeah I was going to say it doesnt take very long, although I havent done one on a 603 yet, I've done it on a 602, took about a half hour. Or did you want book labor time ?

[Brian Carlton]

I was just trying to make some sense of why people do gyrations with all kinds of sockets and extensions and universals to get the GP out, and risk dropping the nuts, rather than simply taking the manifold off.

Seems like the decision is clear.

[speedy300Dturbo]

Yes, I HIGHLY recommend removing the manifold to replace the GP's, especially the job hasn't been done in the last 10 years or so. As far as 6mm hex sockets go, not all are created equal. Try a 1/4" drive 6mm hex socket, it will give more clearance when removing the fasteners from the lower bolts. Additionally, a magnetic pickup tool will be useful if you drop a bolt into a nook and crannie that your finger can't reach into.

Things you can easily do with the manifold removed:

1. Replace fuel injector line clips and rubber bushings
2. Replace intake manifold gasket
3. Clean out intake manifold of crud/carbon/sludge
4. Lube throttle linkage
5. Adjust ALDA
6. Replace shut off valve

[Johnhef]

I plan on giving my alda 1/4 turn when i pull my intake as well, also all my plugs still light, but I'm sure they've been in there awhile so I may change them out as well.

I have a friend with a 606 engine that needs plugs done, I attempted to get to the bad one and realized aint no way with out that manifold off.

[Brian Carlton]

Originally Posted by Johnhef

I have a friend with a 606 engine that needs plugs done, I attempted to get to the bad one and realized aint no way with out that manifold off.

John, better tell your friend to start some daily prayers to the 606 gods.
He's going to need it if he hasn't done them in awhile.

[190D22]

Well the tools I showed would have worked FINE if I hadn't dropped the GP when trying to install the NEW one in cyl #3!!!! I was retarded and took over an hour just to find the damn thing. Turns out all I had to do was slide myself under the car to below the starter and voila it was right there.
My man Ron up at Crown Mercedes was right about needing "to be a contortion artist." Especially for GP#3, there is only 1 (ONE!!!!) way to get the socket extension and that swivel/pivot thing in there. Cyl #1 was Easy, #2 was semi-easy but tedious because I could only do baby increments of ratchet movements with-in the manifold opening. All of you manifold removers are probably laughing right now... but it is cold outside here and I do not feel up to dealing with undoing injector lines and what not JUST to do GPs... So ALL off this that I went through is that much less stuff to take apart and go wrong with the car. Next time I know where the fallen GPs will likely go to... THAT HUGE MAGNET OF A STARTER!!!

Good luck future GP replacers!

[Johnhef]

He just bought the car, it was a trade in. '95 E300 non-turbo. His first diesel. all the plugs have a resistance of about 1.5-2 ohms except #1, 22.7 ohms.

[H2O2]

Not sure if it's been mentioned in this thread yet, but a set of ball head allen wrenches really helps with access to the 6mm bolts on the intake. They allow you to attack the bolt from a variety of angles, similar to a universal. I just re-installed the intake on my OM603 tonight, and found that the ball head allen was the only way I could easily reach the lower manifold bolt on #6 cyl.