Help removing manifold on '99 E300!!! - PeachParts Mercedes-Benz Forum

LightMan · #1 03-04-2004, 04:37 PM

Oh i'm having trouble and then some.

Anyway - '99 E300. I need to replace my glowplugs. I have the plugs and new manifold gasket. I am stuck on the 4 bolts that attach the manifold to the egr. I've gotten 2 of the 4 out, and can't seem to find ANY way to get a socket on the other two, from the side or underneath. I dont want to have to pay $500 at the dealership to do this when I'm two bolts away, the rest is cake. Can anyone help?? Thanks

LightMan · #2 03-04-2004, 06:17 PM

Ok never mind guys I got it off. Apparently those 4 bolts stay put and the only bolt that needs to be removed is the clamp bolt holding the corrugated pipe that goes from the exhaust manifold to the egr... PUll up and the intake and egr/manifold assembly all comes up in one piece!

Now, WOOOOOHOOOOOO I got all 6 glowplugs loose and and out without breaking any off, whew!

I've been told I need a 'reamer' tool to clean out the track for the new glowplugs to go in. Can anyone tell me where this tool is available or how necessary it is? The mb tech at my dealer told me that I need to ream the holes or the new gp's won't go in. Any ideas/experience guys?

fj bertrand · #3 03-04-2004, 06:33 PM

when you put the new plugs in, make sure you use a anti-seize
lubricant-it is compounded with nickel. works reeeaaaallll good!!

as for a reamer, as a field expedient, I cut grooves in an old
glow plug perpindicular to the threads, then screw in and out.l

Then before you put any of the glow plugs back in, crank the engine (make sure the intake isn't going to suck in anything it
shouldn't) to blow any of the scrapings from the reamer out of the cylinders.

good luck!!

LightMan · #4 03-04-2004, 07:59 PM

The glowplugs on the 606 are particularly long and flimsy, its a small miracle to get them out of the head without breaking them off. I wouldn't want to use one of them as a tool of any sort for fear of snapping it and having pieces fall in the head. Anyone have a part # for the proper reamer tool, or know of a comparable one locally available?

LightMan · #5 03-04-2004, 09:48 PM

Also, my intake manifold gasket appears to be still perfectly intact. Do you guys think it's necessary to scrape it all up and install the new one or should I just leave it there and reinstall the manifold??

Rick Miley · #6 03-05-2004, 10:26 AM

Performance Products lists 2 different glow plug reamers, one for $49 and one for $149. I'd bet it is the $149 version. Call Phil and ask if he can get it.

Don't know about the intake manifold gasket without seeing it in person. Is it worth doing the job over again if it leaks?

Congrats on getting the manifold off. How dirty was it inside?

Oh, and uh, noots.

jcyuhn · #7 03-05-2004, 10:34 AM

I'm pretty sure the intake manifold gasket is reusable. Isn't it a thin piece of stainless steel?

It's not a bad job once you learn how to pull the manifold. At least access to the glowplugs is good.

- JimY

LightMan · #8 03-05-2004, 11:24 AM

The manifold and egr were quite dirty. Not clogged shut like a TDI, but give it 150k and I think it would be. 2 hours and a few cans of carb cleaner later, my intake is shiny and silver inside and out!

Anyone else have any ideas on the reamers?

What are the torque specs for the intake manifold bolts, and is there any special pattern of torquing to follow?

LightMan · #9 03-05-2004, 12:33 PM

Quote:

Originally posted by Rick Miley
Performance Products lists 2 different glow plug reamers, one for $49 and one for $149. I'd bet it is the $149 version.

I called. The $149 version is for old loop style glowplugs. The $49 version is what we need for our cars, to clean the pin/pencil style glowplug. WOOHOO, we finally need one part thats cheaper than the old mb's! LOL..

Rick Miley · #10 03-05-2004, 01:48 PM

Uh oh, that still doesn't sound right. If they only have one style for pencil type plugs, then it would be for the OM616/617 type. That would make it way too short for an OM606. So I bet their information is wrong and they don't have the proper tool for the 606. Given PP's reputation regarding returns, I'm not inclined to order one and find out.

benzmark · #11 03-05-2004, 02:22 PM

I just changed the glow plugs on my 99 turbodiesel this week. 75k on the car and they were last changed at 40k. For what my experience is worth, the new plugs threaded in and torqued down easily without reaming the plug holes. Car now runs smoothly and quietly at cold start in the morning. Also reused the manifold gasket (steel) for the second or third time without any problem there. Mark

sokoloff · #12 03-05-2004, 07:06 PM

So the only new parts you need are the glow plugs? Everything else is reusable?

Len
'99 E300TD 60,000 miles

LightMan · #13 03-05-2004, 07:35 PM

I am going to make a post with pictures here pretty soon with everything you need and outlining all the steps of changing gp's on a e300.

Sokoloff, you will need 6 glowplugs, a manifold gasket, some anti-seize, and some torx bits. See my post later on.

gsxr · #14 03-05-2004, 08:11 PM

You don't need to ream the holes at all unless the old plugs were hard to get out, i.e. locked in with carbon buildup. A cheap trick is to hammer the element of an old plug flat and screw it into place. This really should not be necessary unless the engine is seriously carboned up.

I don't understand why anyone would want to re-use an old gasket unless new ones are terribly expensive. If it's a steel shim type it *could* be re-used if cleaned and some liquid dressing was applied (Hylomar, etc). If it's a fiber gasket I would not re-use it, period. The gasket should be ordered when you buy the plugs, IMO. Rick was correct - is it worth saving $14 (dealer retail for the gasket) while risking having to pull the manifold a second time? Remember this is a turbo engine, the intake is under pressure, not vacuum.

The factory procedure is almost useless, doesn't tell you anything, other than tightening torque is 20Nm and there is no mention of reaming the holes. If you apply anti-seize to the threads, don't use a torque wrench!

HTH,

LightMan · #15 03-05-2004, 08:20 PM

My car is all done, and perfect. Runs beautifully with the new plugs and cleaned intake. I used the new gasket, its a thin metal crush gasket type. Could be reused but its cheap so I used a new one. I'm going to post later a detailed thread on the process with pics.