603 remove intake to change glow plugs?
 

I need to change the glow plugs. Will I need to remove the intake or can I get to them with my socket extensions and swivels?

I need to get this done as it's not starting in the now very cold weather, and I don't have a new intake manifold gasket on hand.

What think you?

DS

Some members have been successful with a combination of 1/4" extensions and swivels.

Others will tell you to forget about it and remove the manifold.

I have not done it, personally, so I offer no advice.

I would say since since I have done the job removing the intake manifold is the best way. I broke two sets of 1/4" swivels trying to do it. Also it is difficult to thread them back in and since the head is aluminum you run a big chance of cross threading them. With the manifold off the GP's are even easier to replace than on a OM 617. The manifold is easy to remove and replace. You do need to use swivels for the manifold bolts though.:rolleyes:

Is there any chance of re-using the intake manifold gasket? I've got to get this done asap.

There is a chance you will be able to reuse it but if its been in there for more than a few years it will most likely fall apart upon disassembly. I'd get the gasket before you remove the manifold.

Removing the intake manifold is the way to go - with the proper tool (6mm "wobble" allen bit mounted on a 1/4 socket with extensions) I can remove the intake manifold on an OM603 about 10 minutes.

Dealer
 

The dealer in my area (Central Jersey) actually had the 603 intake manifold gasket in stock - you might try yours. It was a good thing for me because I had ordered the wrong part online...

Thanks, I ordered it from Phil at Fastlane, which is where I get most of my parts. Should get it tomorrow. The nearest dealer is around 100 miles away from me.

Is there anything else to replace? What about the gasket between the intake and the crossover? Do you leave the cross over in place?

Pull the manifold, don't screw around with socket extensions ect. It will take you longer then if you just did the job right.

You will need the manifold to head gasket, because it will surly be almost gone. You should also get the intake to crossover gasket along with the large green oring that seals the crossover by where the egr dumps in. However you can do that at a later date the crossover is only held on by three bolts and pops right off. The manifold is pretty easy to pull you will need to remove a few injector lines and brackets but thats about it. If your egr is still working the manifold will be full of tar.

Did you test the plugs to see if they were bad?
It's below zero here and even when all my glow plugs work, if I don't have my cars block heater plugged in the morning for a hour or so,you better have a very good battery, to keep it turning over until it does fire.

I'll add to the "take the manifold off" camp. Also a good idea to have the little plastic clips for the injector lines on hand, as there is a good chance they will get broken in the process.

I know I must have a glow plug issue since everything else is ok, fuel, compression, turning over fast. And since it always started last winter down to over 15 below, I think I've just lost some or all of the glow plugs. I have no idea when they were changed by the p.o. If there is an electrical problem, I will address it, but they still need to be changed, of that I've little doubt. In fact it's been running rough at start up lately, so all signs point to the plugs.

Losing ALL the GPs' would be hard to imagine, but losing the strip fuse from fatigue is often a problem. Its under the cover on the GP timer. Cheap fix and worth changing as long as you are there. If its OK, then off to the races with removing the manifold.
BTW a ball-end hex tool is what I have found makes installing or removing the hex head bolts easier. There is even one made (by Wiha) that has a gripper that holds the bolt while you lower it down on the tool.
Please be real careful not to drop anything into an intake port while the manifold is off :eek:

Since I'm changing the plugs tomorrow, it may be a little late to ask, but what is meant by using a "glow plug reamer" why is this needed?

A reamer tool especially made to fit into the opening where the GP is in order to carve away any carbon that is built up as it tends to get that way especially if you don't drive hard and fast often. (Italian tune ups!)
Using a GP reamer is not mandatory however.

I usually turn the engine over after removing the plugs, just a few times to blow out the carbon that reaming knocked loose. If you do this, be sure to disconnect the GP cable at the timer by unplugging it first!!

Just be aware that some GP's have been known to have a blob of coke on the shaft that makes removing them difficult without breaking the tip off in the chamber :eek: That brings its on a new set of problems maybe resulting in having to remove the head to get the tip out.
A trick is to unscrew a plug while pulling against it (after unthreading the body) and the tip will hopefully come out of the carbon if its there, also spray some liquid wrench on it too if its stuck.
Basically go easy on this job and hopefully it goes well.

Maybe it won't be too much of an issue. I tune it up regularly, Italian style. In fact, I have very little black smoke, now, at all. The po didn't do this, I am sure. Since I removed the EGR for experimental purposes, I've noticed better and better acceleration. In fact lately she is actually shifting at the indicators on the speedo, which she never did before.