The corrosion is the killer. The shields will not come out in one piece. There is a rusted portion that stays in the head and I'm going to have to find some type of hole saw to clean the residue out from around the plug.

I'll never put the shields back...........

I have a couple of new spare shields if anyone wants them

Sixto
87 300D

Bought a 7/8 hole saw (the OD of the socket) and went at #4 for about two hours. Clearly, the remains of the shield are rusted to the walls of the manifold. Removed a bit of material but still not enough to get the socket onto the remainder of the plug.

Went at it with a small chisel and got another section of the shield out from one side of the plug.

The remainder just won't dislodge.

I'm going to get a 1" hole saw, which I believe is the approximate OD of the shield.

This tuneup remains the ongoing nightmare............and there are three more to do.

Incredible patience Brian!! I would have put that sucker on a lift and pulled the damn engine by now.

I can only hope that you are working on a scheme for custom made heat shields to supersede the original design.

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On some nights I still believe that a car with the fuel gauge on empty can run about fifty more miles if you have the right music very loud on the radio. - HST

1983 300SD - 305000
1984 Toyota Landcruiser - 190000
1994 GMC Jimmy - 203000

https://media.giphy.com/media/X3nnss8PAj5aU/giphy.gif

I don't have much of a choice other than to remove the head. That's really no pleasure.

My replacement design is identical to the design on the 1989 van...........NO HEAT SHIELDS. If the 318 worked fine in 1989 without heat shield WTF are there heat shields on the 2002?

To give the mechanics something to do and the dealership something to charge you for.

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83 SD

84 CD

I'm really curious as to what the dealership would do with this situation. They must have encountered it before............

It's called 'give me your credit card'.

Roy mentioned that Chrysler has a $2K kit for this situation. It's highly unlikely that the dealership would purchase it.

I wouldn't risk this with a dealer. Apparently, if you fail, you must remove the entire engine from this vehicle. Getting the head off while the engine is installed isn't an option.

I assume you've been dousing plugs with penetrating oil? Acetone/ ATF is a nice substitute. I'd spray, apply some torque, let it sit for awhile and repeat. Rocking motion + repeated application of penetrating agent should eventually bust this thing loose.

The plugs are not the problem.

It's the shields that have, effectively, rusted themselves to the bore provided in the exhaust manifold. The shield comes out, minus most of the material that is in the bore (around the plug). Therefore, you cannot get a spark plug socket down there.

Is it possible to get a thin wall socket down on the plug? Grind off some of the outer portion of the socket and see if it fits?

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

I looked at some thin wall sockets for motorcycles. The current wall thickness on the standard socket it about .075" at the points. I'd be concerned that a thinner socket won't take the removal torque. On one of the plugs I must have had over 60 lb-ft. to crack it loose.

If the plan for the 1" hole saw doesn't work out, that option might be the next one up.

One of my plug sockets is a tight fit for one of my engines. I took it down a bit on the outside to make it less sticky. Taking off the chrome seems pretty safe as i would assume it does not contribute structurally.

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

Is the heat shield uniformly obstructing the socket or just in a few places? If not uniformly, you could grind down the socket in the obstructed areas and leave the original thickness in the unobstructed areas.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13