I just got done changing out my glow plugs and thought I would make a post about some tips I could give anyone doing the same. Before I start, thanks for all the others' posts which helped me very much in preparing for this job.

Background- 85 300td- frybrid heat exchanger, SLS, AC, etc = jammed engine compartment.

Injector Line Removal
I took off the injector lines, I tried removing plugs with them on and was having a heck of a time squeezing my hands in there. I didn't find a 17mm flare nut wrench to be very useful (as others have suggested) because I couldn't get the (Flare)wrench on most of the injector side fittings. However I was successful with a standard open end 17 mm (you can hold it at more of an angle and avoid obstructions). The fittings weren't very tight so the extra precaution which the flare-wrench gives was not too important. To loosen the injector line fittings on the injection pump I found that a 17mm crowsfoot was pretty much ESSENTIAL (its also handy for the 17mm injector side fittings). Also you need to remove the fittings on the injection pump in ascending order starting with the one nearest the radiator (cyl#1 I think).

Once the injection lines were off there was a lot more room to get the plugs out. I used 8 and 12 mm gear wrenchs (aka ratcheting box ends) and they worked great. I got some with flexible heads so they are very versatile..these saved a lot of sanity!! cyl#5 is tight!! but if your patient you can get it off slowly but surely. I used a 19/64 drill bit in place of a reamer. It did an OK job (I think??), but on many cylinders I could get the drill bit into the port straight because the bit was too long to get positioned to go straight in. I removed a little carbon but I don't think I did a very good job. I don't think my ports were too badly carbonized because the glow plugs came out easily. I applied grease to the bit and it seemed to be effective in capturing debris. Also, turning the engine over with all the glugs out sounded like it worked..I heard "poofing" air and in theory debris coming out of the ports.

Putting everything back together was straight forward. It seemed pretty necessary to install the pump-side fittings for the injector lines in the opposite order as they were removed. All and All it took me about 4 hours but I was taking my time. Once installed the injector lines need to be purged of air.

Car started right up, glow plug indicator lamp works now..I'm happy

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'85 300td Frybrid WVO Kit

Find an old drill bit and cut/grind it shorter for cleaning the GP hole out.

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84 300D, 82 Volvo 244Gl Diesel

Thats just what I was planning on for the next time I change out the plugs. I was also also thinking about a way to get a little more grip on the bit...maybe squaring off the end a little with a grinder so your fingers have something to turn.

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'85 300td Frybrid WVO Kit

Forgot to mention...I also used "toomanymbz's" advice and disconnected the throttle linkage (just pull cotter pin near fire wall). This really helped access cyl #5

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'85 300td Frybrid WVO Kit