bump, in case anyone missed this last week.

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

Bump for those who missed it

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

I don't own a car with that engine.. but thats a good write up!

Thanks snibble. I've saved a lot of money due to these forums, glad to give something back.

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

For those about to do this job, you'll want to first take a look at the plastic clips on the fuel lines. They get brittle and break, so take them all off before you remove the manifold so that no plastic bits fall down into your engine! Also remove the black plastic cover over the valve cover, to make it easier to work here. Here are the part numbers if you need to replace the clips:
A 603 078 01 41 Bracket (Qty 7)
A 601 078 03 86 Shim (Qty 7)
A 601 078 26 41 Bracket (Qty 2)

And finally, you'll need:
A 606 141 01 80 Intake Manifold Gasket

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Rick Miley
2014 Tesla Model S
2018 Tesla Model 3
2017 Nissan LEAF
Former MB: 99 E300, 86 190E 2.3, 87 300E, 80 240D, 82 204D Euro
Chain Elongation References

Thanks for the addition Rick.

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

I just went through changing all of my glow plugs and had the unenviable task of removing one that broke off in the head - not fun!! See the post about it here - http://www.peachparts.com/shopforum/showthread.php?t=109101.

Anyway, I have a couple of things I wanted to add to the great posts by Lightman and Rick Miley about the glow plug change.

1. In order to get to the bolt that holds the intercooler pipe to the EGR from underneath, you need to remove the smaller noise encapsulation panel. With it out of the way, that bolt is easily accessed. It is also an allen head, the same size as the ones on the valve cover cover.

2. The bolt on the clamp for the corrugated pipe to the EGR was reasonably easy to remove with a ratcheting closed end wrench. When reinstaling that bolt, point it in the direction where you can get to it with a socket with an extension. Makes it muich easier to put on and will make it much easier to remove it the next time.

3. I found no need to remove the windshield washer bottle. But should you want to remove the washer bottle, know what those two pipes are that you have to disconnect. They carry coolant. One carries it to the tank to keep the washer fluid warm. The other carries it away from the tank. If you drain the hose into the reservour when you remove it, you will be draining coolant into the reservoir which will likely cause a smeary windshield when you use it the next time. The two hoses are part of a closed system and neither one is meant to be drained into the reservoir. Also, be careful if you are removing those hoses when the engine is hot because they will be full of very hot coolant. Believe me, I know.

4. When covering up the holes in the head after you have removed the manifold which is an excellent idea, duct tape works well too.

Anyway, thanks again to Lightman and Rick for the great article. it was a huge help and gave me the confidence to attack my problem. Probably saved me over $2500 since the glow plug broke off and that's what the dealer would have charged me to remove a broken glow plug if they broke it off which I think was likely.

Len

Will this process work with the '96 - '97 Non-Turbo 606?

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Deuce
'02 CLK430 (Nightwing) 54K
'11 ML350 109K
'21 VW Atlas (Wife's Rocket)
'94 Bronco XLT (Son 1)
'06 Honda Odyssey 180K (Sold)
'02 E320 151K (Sold)
'96 E300D (RIP Riggo - 12/16/2010) 198K
'03 Honda Odyssey 34K (Sold)
'95 E300D 145K (Sold)
'01 Mazda Tribute 19K (Sold)

Intake manifold removal will be different. But the plugs themselves are the same.

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Rick Miley
2014 Tesla Model S
2018 Tesla Model 3
2017 Nissan LEAF
Former MB: 99 E300, 86 190E 2.3, 87 300E, 80 240D, 82 204D Euro
Chain Elongation References

I just changed mine today using your directions. Thank you very much. It took me about six hours, but I was very careful and i was not in a rush. The EGR connection is the worst part. I did remove the washer fluid tank, but I was able to remove the cooling line unit from the tank so that I did not have to open the coolant lines. For the #2 wire I had to disconnect the adjacent fuel fine to remove the glow plug wire. This made it much easier, however, I had to bleed and crank to get the car started. I do not care for the way the wires connect. I would prefer a threaded connection.

I tried using Simple green to clean the intake.....waste for time and money. B100 did the trick.

Although this job appears to be very involve I believe it took me less time to replace these as it took me to replace the five glow plugs on 1985 300D.

Once again, thank you for your instuctions.

Glad to have helped any and all that have read the guide. It feels great to do it yourself!

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

Dear Dave,

Thank you very much for a brilliant article.
It helped me tackle the job which I was dreading.
I did one step which may help other readers.
Rather than remove the EGR valve with the manifold, which can theoretically damage the corrugated pipe which would be expensive to replace, I managed,with a bit of a strugle, to remove the 4 bolts which bolt down the inlet manifold to the EGR valve. I did not have to work under the car that way.
Therefore the manifold was able to to be removed without disturbing the vaccum pipes.
The glow plugs came out a treat, they were luckily not seized up.
Incidentally removing the washer bottle was a very good move, without removing that, the access would have been very difficult.

Thank you once again Dave.

Orthomechanic

Hey there, you're welcome...glad to help.

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

Just have to chime in and say thanks! This is the second time around for me, as I found these instructions so complete and the job so straightforward when I did it the first time last Spring, I only replaced two of the the six. I am just about ready to button up having replaced #1 and #5 today. Great post, and thanks a million. It literally saved me about $1400 for two sessions. Jim

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Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

Yes, I'd like to say thanks to Lightman as I needed this procedure today to remove the IM to access two troublesome bolts on my leaking fuel shutoff valve.

I'll add a couple of photos a minor contribution to this work. A total of 16 bolts are removed to enable removal of the IM. 14 are the bolts holding the IM, the other two are referenced in the photo below:

14 bolts removed here:



10mm bolt on right is accessed from above. 10mm bolt on left is accessed from below. Manifold is ready to be removed, it's that simple:



I'm going to refresh this o-ring. This is at connection between the pressurized air from the I/C to the EGR valve.



There's a lot of "spatter" from exhaust or oily vapors and one of these connections is leaking. It could be the EGR clamp that's leaking.

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