Below is an extract describing the kit that I was referring to:

Phil


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Diesel Engine - Cylinder Head/Glow Plug Thread Repair
Date: January 2004

Order No.: P-B-58.20/134

Supersedes:

Group: 58

SUBJECT:
ENGINES 601, 602, 603, 604, 605, 606, 611, 612, 613, 628, 646
REPAIR KIT FOR GLOW PLUG THREADS IN CYLINDER HEAD

A repair kit for damaged glow plug threads and/or broken off glow plugs in the cylinder head has been developed. This repair kit allows for the drilling-out of the glow plug bore and the installation of threaded inserts. As a result, the replacement of the cylinder head due to broken glow plugs (as an example) is no longer required.

The repair kit can be ordered as a Special Tool: 611 589 00 99 00.

__________________
'95 E300 Diesel, 264,000 Miles. [Sold it]

That was the kit we got. It had some thread chasers, brush, helicores, etc, etc. Even had a helicore that was the same size as the 606 glow plug but since it is the same size, you cannot fit the plug into the helicore.

__________________
01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
03 SeaDoo GTX SC Yellow
04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow

Okay. Here's the saga so far.

I've completely removed the cylinder head. It really wasn't a bad job. Lots of steps, but nothing that I couldn't handle.

The machine shop is very comfortable with this cylinder head. I'm in the process now of having all of the intake plumbing cleaned and spent some time at the Mercedes dealer yesterday ordering odd parts that I will need.

Here's a few photos of the job so far:

http://www.imagehostplus.com/v2/is.php?i=654276&img=100_0291.jpg

http://www.imagehostplus.com/v2/is.php?i=654277&img=100_0292.jpg

http://www.imagehostplus.com/v2/is.php?i=654278&img=100_0293.jpg

http://www.imagehostplus.com/v2/is.php?i=656477&img=100_0304.jpg

http://www.imagehostplus.com/v2/is.php?i=656478&img=100_0305.jpg

http://www.imagehostplus.com/v2/is.php?i=656479&img=100_0306.jpg

http://www.imagehostplus.com/v2/is.php?i=656480&img=100_0307.jpg




I've bought ALL of the tools for this job, special injector socket, guide pin removal tool, prechamber collar ring, and prechamber removal tool. I would imagine that others will be doing this same job soon so I'll loan the tools for a small fee and deposit.

Well I'm in the position where I may need to do this myself (with a mechanic friend of mine) rather than pay $2500++ in labor. (Yeah, this thread is 6 months old but so far this is the only one I found where someone did it themselves).

How many hours did it take you to pull the head? I assume the procedure is written up in the factory manuals?

Thanks.

Chuck

I was able to remove my broken glow plug without removing the head by drilling it out. Others have not been so lucky. See all the details here:

http://www.peachparts.com/shopforum/showthread.php?t=109101&highlight=glow+plug

Len