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  #1  
Old 12-28-2020, 10:47 AM
Ian White's Avatar
machinemanjr
 
Join Date: Jan 2009
Location: Spokane, Washington
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Soliciting Advise: MB Dealer Broke OM 606 Glow Plug off in head

I recently took my 95 E300D to MB of Spokane for dealer service of my 6 glow plugs. The factory tech broke off the GP in Cylinder #2 off on Christmas Eve (Merry Christmas , indeed).

They said they would attempt to drill and extract it today. If that is unsuccessful, the head will need to be pulled--which the dealer said was a ~$3500 job and recommends changing the lifters, valves, timing chain, guides, IP seal (small leak) etc.

I am looking for advise, IF they fail at extracting the broken glow plug and the head does need to be removed, do I have any case for suggesting the dealer pay for this repair for the cylinder head? I brought it to the dealer for expertise, because I didn't want to break one off doing the repair myself.

What are my options? What have others done in this circumstance?

I want to be firm but also realize on a 25 year old car, things happen.

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  #2  
Old 12-28-2020, 11:40 AM
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Wow that's not nice. I assume they have the proper jig to line up the drill bit. If they do have the jig it should come out alright. I think an experienced technician would apply penetrating oil while the engine was warming up and use a impact dialled into 30 ft lb or less torque to extract them. Maybe see what the technician did to prevent breakage or was he even aware they can break? I sure hope they have that jig or your car may not be drivable until the head is removed. I'm feeling your pain!
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  #3  
Old 12-28-2020, 12:10 PM
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I would want to know what kinds of precautions they took before snapping the plug (warming up, penetrating oil, setting a torque limit, etc....). If they really took no precautions, I think they should bear some responsibility. When my indie was having a hard time getting a plug out of my 98, he informed me of the fact and I explicitly gave him the green light to go for it, absolving him of responsibility. Fortunately the plug came out.
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  #4  
Old 12-28-2020, 12:17 PM
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Hopefully it will drill out.

About replacing valves, lifters etc. IF the head must be removed, how many miles, how did it run, did it start well cold, did it burn oil? Valve seals and a timing chain may be all you need. Compression test results before throwing parts at it would be good information.

Good luck!!!
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  #5  
Old 12-28-2020, 12:37 PM
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I doubt they are going to pay for it, but also I wouldn't replace anything other than maybe the lifters unless it actually needs it.
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  #6  
Old 12-28-2020, 03:11 PM
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I would definitely threaten legal action if they attempt to charge you for the job. While it can be argued that they did their best and **** happens, it can also be argued that they intentionally participated in a sequence of events that led to a substantial increase in estimated spend. Don't let them screw you over.
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  #7  
Old 12-28-2020, 03:35 PM
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I am surprised that the dealer did not warn you the GP could break off and asked you to sign a waiver. I doubt the dealer would cover the costs of removing the head unless you have been keeping the maintenance schedule to the dot over the last 25 years at the dealership. What may happen is that they will split the costs with you if and only if they replace all or some of the parts they recommended. In other words, you are screwed.
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  #8  
Old 12-28-2020, 04:20 PM
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I would think they would have insurance that would cover this. Most business liability insurance policies I've seen have an errors and omissions provision that covers this type of incident. In the early 1980s a technician at the Volvo dealership in Houston, TX, incorrectly installed a valve spring which ended up causing the piston to strike the valve and causing all sorts of engine problems with my cousin's 1969 Volvo 164. The dealership made a claim on their insurance. Initially the insurance wanted to total the car, but my cousin pestered them a bit and they ended up covering the cost to repair the car.

I also remember a story from a member here who took a w210 diesel to an independent garage to either change the glow plugs or remove a stuck glow plug (I can't remember which) and the independent shop screwed up the head in the process. I seem to recall the shop's insurance covered it, but they may have totalled the car.

I think I would want to nail down with them exactly how they plan to handle themselves if they can't successfully drill out the broken plug before authorizing them to try to drill it out. It rather seems to me that they are doing now (explaining/warning that expensive repairs may be occasioned by the work they are about to undertake) what they should have done before they started the job in the first place. Personally, I'd be wary of authorizing anything in writing or verbally now that they may later attempt to claim waives liability for their initial error.

Good luck and sorry that happened.
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  #9  
Old 12-28-2020, 04:34 PM
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$3500 may total out the car's value.
You live in a moderate climate.
Install 5 good glow plugs and keep driving the car.

This is only an option if they don't try to drill it out and bugger that up. If they do that, then you are mildly screwed.

I drill one out on a 606.
Drilled just shy of the threads. Using a dremel with a small carbid tip, I cut a grove in the "ring" of the remaining glow plug body into the threads. Using a small chisel, I was then able to turn it out, or bend it in on itself with a needle nose pliers. The grove in the threads did not effect the ability of the new glow plug to seal.
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Previous:
1983 240D, on WVO
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1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
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  #10  
Old 12-28-2020, 05:09 PM
t walgamuth's Avatar
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I think driving on five might be a good alternative. You'll have to use block heater when cold to get it going probably but that is no biggie.
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  #11  
Old 12-28-2020, 05:17 PM
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Depends on where he lives. In some states you can’t pass inspection with a bad glow plug.
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  #12  
Old 12-28-2020, 05:19 PM
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But driving with five plugs is fine even in cold climates… I did it for a year and a half until I had to pass inspection.
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  #13  
Old 12-28-2020, 05:20 PM
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Never needed the block heater even when really cold.
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  #14  
Old 12-28-2020, 05:51 PM
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Join Date: Jul 2019
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Quote:
Originally Posted by Volvo Diesel View Post
I would think they would have insurance that would cover this. Most business liability insurance policies I've seen have an errors and omissions provision that covers this type of incident. In the early 1980s a technician at the Volvo dealership in Houston, TX, incorrectly installed a valve spring which ended up causing the piston to strike the valve and causing all sorts of engine problems with my cousin's 1969 Volvo 164. The dealership made a claim on their insurance. Initially the insurance wanted to total the car, but my cousin pestered them a bit and they ended up covering the cost to repair the car.

I also remember a story from a member here who took a w210 diesel to an independent garage to either change the glow plugs or remove a stuck glow plug (I can't remember which) and the independent shop screwed up the head in the process. I seem to recall the shop's insurance covered it, but they may have totalled the car.

I think I would want to nail down with them exactly how they plan to handle themselves if they can't successfully drill out the broken plug before authorizing them to try to drill it out. It rather seems to me that they are doing now (explaining/warning that expensive repairs may be occasioned by the work they are about to undertake) what they should have done before they started the job in the first place. Personally, I'd be wary of authorizing anything in writing or verbally now that they may later attempt to claim waives liability for their initial error.

Good luck and sorry that happened.
This is the route to go. Ask them to make a claim on their G/L or E and O insurance policy. If they balk, tell them your lawyer will be in touch with their general manager.

then, simply have your lawyer write up a nasty gram addressed to their General Manager asking for the name of the company that carries their G/L and E and O insurance coverage, policy number, insurance agent's name, address and direct dial telephone number.

I've seen this strategy work in a number of cases. The dealership pays a lot of money for their G/L and E and O insurance polices; it now time for them to make a claim.

Remember, THEY are the ones who screwed up your car, NOT YOU.
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  #15  
Old 12-28-2020, 07:41 PM
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I would make sure they have the proper Gig/Kit to drill out the Glow plug and someone who has been trained to use it before they do the work.

If for some reason the Threads get buggered up doing the job there is also supposed to be a Kit/gig that can replace the threaded ares with a threaded insert.

The main issues is they cannot drill in too far and mess up the seating area where the glow plug seals. The Glow Plugs seal on that tapered/angled
shoulder just behind where the tip/element ends.

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