I need to pull the glow plugs out of my 603. What is the best way to get to them? A real long socket extension? Also are bosch plugs ok I can get them locally for $10.99 each.
Btw I was going over my new purchase today. I fired it up and pulled the oil dipstick out and removed the filler cap, there was no blowby, not any at all, not even a hint. Also all the filters, hoses and even the hose clamps on the car are MB. It seems to have dealer maintained. So far only a little surface rust found, nothing that can't be quickly fixed. Except for the bumper thats shot.

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1999 SL500
1969 280SE
2023 Ram 1500
2007 Tiara 3200

I recently replaced the GP's on my '87 300D by removing the intake manifold. Old posts describe the possibility of doing it with the manifold in place, but I found it impossible. Hex wrench with ball end was the ticket for removing the intake bolts. It also gives you the opportunity to replace the leaky intake manifold gaskets, clean the crud out of the crossover pipe and manifold, and replace the temperature sending unit and shutoff valves. I replaced Beru GP's with 195K with the same, but Bosch should be equivalent. Used antisieze compound and gentle torque with GP's and fasteners per GSXR's recommendations.

A Snap-on FSFSM12 3/8" drive 12mm deep universal socket is helpful in getting the first few glow plugs out. If you want to change them all, I'd advise pulling the intake manifold. Bosch or Beru glow plugs are recommended.

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Brian Toscano

Save yourself the aggrevation and remove the intake manifold, it makes the job MUCH easier. Also be sure to replace all the little plastic clips that hold the injection lines to the manifold. They look like they are unnecessary but in fact it is not unheard of for a loose and vibrating injection line to wear through where it contacts metal. Also, as froghunter mentioned, at a minimum allow yourself some extra time to clean up the inside of the manifold and crossover pipe. You'll be amazed how much crud is in there.

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LRG
1987 300D Turbo 175K
2006 Toyota Prius, efficent but no soul
1985 300 TDT(130K miles of trouble free motoring)now sold

Thanks guys yeah I want to pull the manifold off anyway. I'm sure the egr has done it's job well. The egr will not be going back on. I lack a manual right now how many gaskets do I need? And while I'm in there the temp sending unit and shutoff valves. Also where do I get those little plastic clips that hold the injecter lines on? One of mine is about to fall off.
I just looked at fastlane and I didn't see the temp sending unit or shutoff valve listed. Maybe I missed them are these a dealer item?

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1999 SL500
1969 280SE
2023 Ram 1500
2007 Tiara 3200

At a minimum you'll need two gaskets. The manifold to head and crossover pipe to manifold gaskets. You'll end up removing the crossover pipe from the turbo but that has an O ring gasket that can probably be used again. Check it though. I didn't bother to replace my shutoff or temp sending unit, I'm too cheap I guess. Mine looked (and still are) fine. The plastic clips are available from the dealer and are pretty cheap, don't remember exactly but about $2 a piece. If you call Phil I'm sure he can get them for you.

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LRG
1987 300D Turbo 175K
2006 Toyota Prius, efficent but no soul
1985 300 TDT(130K miles of trouble free motoring)now sold

I would caution against the use of ball ended hex drivers. I tend to think they are more likely to strip the heads of the bolt... ? I have 3 603 engines and have pulled the manifold a bunch of times. I use 1/4" drive 6 mm hex drivers and a universal.

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Brian Toscano

I think I will just call Phil up and see if he can ship me all the parts I will need. I just ran outside and pulled the crossover pipe off. It is all gummed up with a thick tar like substance! The manifold doesn't look like a big job to get off. Maybe I can do it this weekend. Does anyone make a paper manual for this engine, I can't find one. I hate flying blind. (well half blind now thanks!)

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1999 SL500
1969 280SE
2023 Ram 1500
2007 Tiara 3200

Hatterasguy,

I pulled my intake this past summer. The crossover and intake had some junk in them but not as bad as I expected - like you see on the TDI pictures. I found some "Intake Manifold Cleaner" , either gunk or STP brand I believe that really did a good job. 2 Cans and some spraying / scrubbing and they were 95% clean to the metal. My only fun was getting the bolts through the gasket on #5 to start correctly for some reason. All pretty easy.

Let me know how the clow plugs go, that may be coming up some time also.

Chuck

Rather than using a needle nose, I STRONGLY suggest using a slim-head telecscoping magnetic pickup tool. (Looks like a small radio antenna).

Replace the intake manifold gasket and as mentioned, the injector line clips and rubber shims. Here's a list of the latter, thanks to "Gsxr":

603-078-01-41 Quantity 6 Injector line clips (2-line)
601-078-20-41 Quantity 2 Injector line clips (3-line)
601-078-26-41 Quantity 4 Injector line clips (standalone)
601-078-04-86 Quantity 8 Injector "3-line" rubber shim for brackets (will need to be trimmed to fit the lines in which only one or two lines are clamped)

My low tech solution to prevent dropping parts into the abyss of space below the intake manifold is to pull an old T shirt under the manifold and stuff it in so that the bolts will fall on top if I drop one (or more). Maybe it's me but even if I use a magnet or needle nose, I still manage to occasionally drop them and God knows I've wasted way too many hours fishing things out of small, inaccessable and dark places.

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LRG
1987 300D Turbo 175K
2006 Toyota Prius, efficent but no soul
1985 300 TDT(130K miles of trouble free motoring)now sold

The "baby" sits outside in the cold? I'm shocked

Sounds like the prices in Boston are up in the stratosphere like here on Long Island. You don't need to spend 500K for a house and a 2 car garage. But you will spend 350K to do it.

But, these prices are nothing compared to our friends out west. The prices in the Bay Area are truly mind-boggling.

I'll bet Sixto could confirm this.

Let me put it this way, nobody aspires to live in a $500,000 house in the SF Bay Area.

As for accommodations at my house, the MBs are too long for the garage and the Caravan with conversion top is too tall.

Sixto
95 S420
87 300SDL

Sixto, is there really a house in the Bay Area still below $500K?
I'm moving