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  #1  
Old 12-25-2005, 03:46 PM
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Exclamation 95 Mercedes E 300 606 Diesel Repair Question

Greetings,

I have a 95 Mercedes E 300 with the 606 diesel. I was in the process of replacing a dead glow plug when I believe that I have torn the threads right out of the head. The glow plug turns, but does not come out.

I'm about ready to remove the cylinder head. Using AllData as a guide, the job so far has been very straight forward. Not much different than the old 5-cylinder turbo diesel that I did a couple of years ago. The dual cams is some extra work.

Question is that I need to get this head to an expert machine shop who is comfortable with this head. I see where Mercedes offers a helicoil repair kit for this because of this very problem. Looks to me that this is going to have to be done with the repair square with the glow plug's point, no room for error.

Any suggestions on working this head? I have the tools to disassemble including the prechamber removal tool. Has anyone been this far into a 606 before?

Mine has 137k miles.

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  #2  
Old 12-25-2005, 09:53 PM
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You likely broke the glow plug off at the threads and the threads are still in the head. Not an uncommon problem. Happened to me. Do a search for "glow plug" and my user name, "sokoloff," and you'll see what I did. Had to drill mine out with the head in place.

Len
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  #3  
Old 12-25-2005, 10:43 PM
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I tried it and screwed up the head. Almost needed a new head. Try getting yourself to a machine shop unless you feel really lucky. I shoulda quit while I was ahead. BTW, that kit they mention doesn't have helicores for your glow plug. Believe me. I had the kit in my hand and none of the helicores would fit the GP. If you are off even a hair, you will screw something up. So, do you feel lucky? I tried it and had a MB tech help me and even then, there was an off angle hole.
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  #4  
Old 12-25-2005, 11:05 PM
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Oh, trust me. I have no intention of trying this one myself. It is DEFINITELY a "pull the head and take it to a machine shop" project.

The glow plug threads have to be square to the bore for the glow plug's stem. I imagine that the machine shop will use the same equipment for valve guides as they have to be square to the valve seat.

No home brews for me. The threads are definitely gone.
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  #5  
Old 12-25-2005, 11:12 PM
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Quote:
Originally Posted by tony1963
Oh, trust me. I have no intention of trying this one myself. It is DEFINITELY a "pull the head and take it to a machine shop" project.

The glow plug threads have to be square to the bore for the glow plug's stem. I imagine that the machine shop will use the same equipment for valve guides as they have to be square to the valve seat.

No home brews for me. The threads are definitely gone.
Problem is that it has to be at that just right angle which is not perpendicular to the head. It is angled down and sideways so that makes it harder. Machine shop has the angle drills to make a hole at whatever angle they choose. They even said it would have cost me less to have them drill it out than to fix my f**k up.
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  #6  
Old 12-25-2005, 11:18 PM
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I'm hoping that my machine shop is comfortable with this job. I plan to have all of the glow plug holes helicoiled to avoid this problem in the future.

Pulling the head once on this beast is enough for me!

Wish I could bill someone for this.
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  #7  
Old 12-25-2005, 11:24 PM
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Quote:
Originally Posted by tony1963
I'm hoping that my machine shop is comfortable with this job. I plan to have all of the glow plug holes helicoiled to avoid this problem in the future.

Pulling the head once on this beast is enough for me!

Wish I could bill someone for this.
If they cannot drill a hole then they have other issues. What I would do is coat the entire GP body from the threads to the end of the body and not the glow plug tip with antisieze and pull it out once every couple of years. I didn't have much build up of carbon. Just the threads siezing in the head
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  #8  
Old 12-25-2005, 11:27 PM
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Yes, I plan to do that once everything is ready. I've replaced only two glow plugs on this car over the years and the ones that are OEM are frozen in place.

I plan to pull and repaste the threads every two years.
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  #9  
Old 12-25-2005, 11:38 PM
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Quote:
Originally Posted by tony1963
Yes, I plan to do that once everything is ready. I've replaced only two glow plugs on this car over the years and the ones that are OEM are frozen in place.

I plan to pull and repaste the threads every two years.
IMO, that should do it. After all, that means you clean the manifold too which cannot be bad.
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04 Tailgator 21 ft Toy Hauler
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  #10  
Old 12-25-2005, 11:43 PM
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Well, I suppose. I'm taking the manifold(s) to the machine shop next week for a cleaning. There is the main manifold, the air plenum tube and the EGR with the butterfly. I've pulled the butterfly out of the air plenum tube and the main manifold for cleaning.

It is really gooped up in there. Looks like the EGR is the dirty bird.
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  #11  
Old 12-25-2005, 11:53 PM
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EGR itself they won't hot tank or at least they didn't want to with mine. Manifold you can scrub yourself but since you have it out, why not pay them a few bucks more to hot tank it for you/
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05 Polaris Sportsman 800 EFI
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04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow
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  #12  
Old 12-25-2005, 11:57 PM
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I am taking it all to the machine shop. I pulled the mechanicals out of the air tubes first.
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  #13  
Old 12-26-2005, 05:14 PM
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I had the same problem, don't drill it out. I ruinied my head and am in some real debt getting it replaced. good luck
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  #14  
Old 12-26-2005, 11:34 PM
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Quote:
Originally Posted by tony1963
Greetings,


Question is that I need to get this head to an expert machine shop who is comfortable with this head. I see where Mercedes offers a helicoil repair kit for this because of this very problem. .......
I believe that Mercedes came out with a kit that allows you to remove damaged/stuck glow-plugs from these engines, without removing the head.

This is different from the helicoil repair kit that you are mentioning.

May be worth your while to check it out.

Phil
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  #15  
Old 12-27-2005, 12:09 AM
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Quote:
Originally Posted by pberku
I believe that Mercedes came out with a kit that allows you to remove damaged/stuck glow-plugs from these engines, without removing the head.

This is different from the helicoil repair kit that you are mentioning.

May be worth your while to check it out.

Phil
I and a couple of MB Techs checked that kit out before. It was complete but we didn't see much that helped other than the wrong sized helicores for that particular plug.

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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
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