Terrific write up - thank you!

Mine was a little different- no turbo, hence slightly easier IMO (I didn't have to get under the car )

My GPs came out pretty easy- only had trouble with 2. I found that using a small butane torch to heat up the area just around the GP helped tremendously- just don't burn any wires or vacuum lines!

Patience is the key. I cleaned out the intake ports using a wire pipe cleaner and vacuumed out what I could- rotating the engine so the valves were closed as I worked.

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1995 E300 diesel

seven days and finally a successful 606 6 GP change out badge!

'95 E300D.

The big difference from the main writeup is the crossover manifold assembly and did not once need to get under the car.

Went through a couple calls to Phil (1 order), 2 cans of Liquid Wrench, many trips to the hardware/parts stores (Ace, Sears, Napa, Schucks and Harbor Freight) and a few ice packs for the back from leaning over the car so long.

#'s 2, 4 & 5 came right out.

#1 came out on day 2, #6 came out on day 4, #3 came out today.

Lots of Liquid Wrench and patience. Starting the car and letting the head warm up was the biggest help.

You will see the tip of #4 cut, that was a test to make sure the wheel I had selected for my Dremel could cut the tip off in order to use a standard size socket as a deep socket will not fit due to a part on top of the IP (looks removable but I didn't try too hard). After I rounded off #3 I tried an assortment of bolt extractors. In the end, the Ace bolt extractor got the required grip, all the others spun.

Thanks again Lightman and all other providing feedback on this post!
Cheers!
Erik
'95 E300D 230K miles (6 GP replacement )

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That's one heck of a first post.

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2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900

erik - don't forget to ream the GP holes...

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1995 E300 Diesel
2002 GMC Duramax CC LB 4X4

Thanks connerm, I've been lurking almost a year now studying different posts working up the nerve to dive into some of the more skilled (beyond oil changes) maintenance.

curlytom -- thanks for the advice, I don't have the reamer (yet) but the manifold comes off again next weekend when I dive into the o-ring replacements with Viton. I have the spline socket on order with the local Benz dealer, I'll take this opportunity to get a reamer from Phil and get some of that junk knocked out of there.

Cheers!
Erik
'95 E300D 230K miles (6 GP replacement )

Dude,
Reaming the gp hole is fine, but the problem is clearly defined by looking at the barrel between the threads and the element. You said 2,4, and 5 came out easily. Its obviously the carbon on that barrel causing everyone's problems. What say the experts about removing a couple of thousandths from the barrel (on a lathe)? I'd consider doing it to a new set before installing them. Way to go Erik.

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2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900

How'd you know I have lathe j/k, I do happen to have one however, knocking off material on the gp barrel would leave room for carbon to sneak into the barrel area creating bigger problems wouldn't it? It was my understanding (through posting in this forum), the root of the problem of build up around the barrels is that the gp may not have been seated all the way in the chamber, leaving room for the gunk to creep into the channel.

Yes, the Glow Plug is supposed to seal on the tapered sholder between the GP Body and the tip.

So far no member has reported inspecting the GP seating areas inside of the head and finding a problem.

Beru makes some special grease to coat the whole part of the Glow Plug body below the threaded area.
But, I cannot see why Never-Seez would not work.

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84 300D, 82 Volvo 244Gl Diesel

Why not coat the threads of the new GP
with cutting oil and gently trial-screw them in all the way--or a tap--just to clean and clear the threads to allow the GP to seat properly. Then remove the GP, clean off the cutting oil, and permanently re-install with anti-seize. Seems the carbon buildup is from the GP not being screwed in all the way--probably out of fear.

Hello, Could anyone tell me if they have swapped out Glow Plugs in a 1997 E300D? From the look of the pictures Lightman was nice enough to provide looks very different in my 1997. THe corrugated pipe and egr assembly looks to be on the opposite side of the engine then where they are on this 98-99 swap. This is realy concerning me now since I need to get this job done tonight since my wife needs her car to go to work.

Can anyone provide me with pictures and/or diagrams on where these parts are on a 1997 E300D? I purchased a CD on this model but just found out it is not mac compatible so I am SOL>

Because the carbon buildup in the chamber is well past the end of the threads and the pencil style reamer clears it out so the gp can work correctly. Hope this helps.

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2004 Ram 2500 Cummins HO
2000 Jetta TDI
1999 E300 (sold)

Don't sweat it. On the non-turbo diesels this is cake. Just remove and move on to the next task.

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#dieselFLEET
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'97 E300
'99 E300

You guys were right, it was no sweat. I have five out and just put some more Liquid wrench on the stubborn one. I was nervous since this was my first job and the 1997 E300D is not the same as the 1998-99 engines. In fact they are 180 degrees different. Will ream out the holes tomorrow. Boy I couldnt believe how much gunk was built up in the intake manifold. That crud is nasty and is tough to come off your hands plus your clothes.I hope that after cleaning these orificies out and installing new GP's that this car will now get over 30 mpg on the highway and have more power. It was a dog before.

BYW what O-Rings are people talking about replacing? New to diesels and would like to make sure all things are covered in this my wifes new car. SOld the 2002 Prius because it felt like she was driving a tin can and I didnt feel she was safe enough driving 100 miles round trip everyday. Sacrificed some MPG for a nice safe ride and was lucky to pick this up for $3400 with 184,000 miles and nice body and paint job.

The new GP's will not affect power or mileage. The probable cause of those issues is the gunk in the intake. That engine has a variable resonance intake manifold, with flapper valves... these all must be clean and working properly in order to get full engine power. The fuel economy should be at least low 30's on the freeway, if not higher.

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Dave
Boise, ID
Check out my website photos, documents, and movies!

Been there done this with gunk--Runs like a new car after the intake is clean again--

Ever seen the resonance valve "vain" vibrate and crack off and lodge in the intake? I've had this happen twice now in 20K. . .

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Mark
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THE WHITE FLEET
2016 GLE300d 4-MATIC 38K BROWN!
2012 S350 Bluetec==94k WHITE

2007 ML320 CDI==166K WHITE (FOR SALE)

Under new management:
2005 E320 CDI--140K--WHITE
1995 E300-Diesel-133.5K--THE CAR IS BLUE
1986 300SL--97.5K (European) AND WHITE. Back in Europe!
1991 190E 2.3-73K California Perfect.--WHITE
1995 E320-Wagon-159K--WHITE (recently scrapped)
1987 300D Turbo-213K--WHITE
1987 190D 2.5 Turbo-288K--WHITE