W210 E300D TurboDiesel #3 Glow Plug Replaced, NO PROBLEMS With the Plug Removal
 

Big relief. Anxiety was pretty high as this is the second replacement for this plug in the 120k miles I have been driving the car that I have done. Didn't use steady force, just kind of swung the ratchet wrench in a pattern to mimic an impact wrench. After a few pops it came loose and I turned it out without the wrench handle, using my fingers on the extension bar.

Putting it back in with 27 N-m after lubing the threads and metal shank with high temperature anti-seize seemed a bit extreme, as it socked down pretty tight. I loosened it to see how it felt and it came loose without making the torque wrench click. Then I tightened it to 27 N-m again and figured it was ok.

I have to do some work on the fuel lines too while I am "in there" so I will get back on it in the morning.

This plug failed and I got no CEL indication. I have my ScangaugeII plugged into the OBDII port, which may be interfering. I have never been able to get that gadget to read codes - after nearly a month it still just tells me it sees no codes and then the system is not ready. But it does help me with mileage - I got 31 mpg the last 200 mile business trip Wednesday and Thursday. Not bad for an average speed of 67 mph. Jim

Good for you Jim.

I take it you had slightly rough cold starts and found the bad one with your multi-meter?

Yes, it is amazing how one plug being bad can cause the engine to rock around and smoke at start up. The multi-meter test was conclusive - open circuit on #3 and all the rest are 1.2 to 1.4 Ohms. After replacing the glow plug in cylinder #3 it reads the same. The plug by itself read 0.6 Ohms. I also noted the plug on the end of #3 was not all the way on. Might have contributed to its demise.

Now I am off to the car wash to blast out the intake manifold. Ugly goo inside, but nothing like the first time I did this job. Right around the EGR valve the stuff was pretty thick, and just inside the manifold from the connection to the EGR valve, but not enough to start closing off the flow area at the manifold to head ports.

Jim

Job is all done, went back together without too much drama. Did the fuel filters and air filter. Dropped the primary filter O-ring into the black abyss of the engine compartment and had to rush over to the dealer to get another.

Filled the new filter with Red Line Diesel Fuel Catalyst and then cranked for at least a minute before it fired up. Runs nice and smooth. Starts from cold fine, no shaking, knocking or smoking.

Took me nearly 24 hrs in lapsed time, and probably 6 hours of actual working on the car to do the whole job, including driving the intake manifold and EGR valve to a car wash and blasting it as clean I cold get it.

Thank again for the detailed procedure and photos Lightman!

Jim

My '05 CDI had two plugs go out during the winter and I could not even tell any difference in start ups, took my time about having it checked since I wasn't having a problem starting. It was repaired under warranty, and SM said they had had several with CEL for GP's that didn't bring in right away do to no starting problems even in IL cold winter. I have about quit looking at GP light for starting the car now days, I just start it like a gasser these days.

So far I have no compliants about the car other than would like to have had AWD in the car, but I guess you can't have everything. :D