Help need !!Broken glow plug ! What to do ?

alphred · **Posted:** Sun Jun 26, 2011 1:47 am

I tried to take out glow plug no 2. The GB have boken near the tread...

[img][img]http://nsa27.casimages.com/img/2011/06/26/mini_110626074453902583.jpg[/img][/img]

Can i use a «turne left tool» ?

I hope to find a other solution than taking of the head !!!

racertracer · **Posted:** Sun Jun 26, 2011 1:59 am

You will need an extractor but I am not sure which one will be good for this situation, others with experience will need to advise you. You will need to go slow and easy.

Anyway you are in a tough situation and I wish you luck.

alphred · **Posted:** Sun Jun 26, 2011 2:48 am

Thanks racertracer, I am a little anxious at the moment !

for the extractor i know 2 types. The conic one, that you screw by the left or the other one that you use a hammer to push it. I think that the conic one will put external force and will not help to take the GP out.
And for the other type, i dont want to loose part in the engine, by the impact, and vibration.
I also know, by personnal experance, that extractor can broke in the hole !! :banghead:

It's 3 a.m and i live a bad moment :dizzy:

I hope my English is not too bad !

ATXKJ · **Posted:** Sun Jun 26, 2011 7:15 am

The photo seems to show 2 issues

1) the small end of the Glow plug ~ 2 cm long 5 mm diameter is gone
2) the metal covering with threads is gone

your extractor may be able to pull the metal covering out (it looks like it's crimped to the nut)

but you still have the small end of the plug inside the head

I think you need to pull the head

Wobbly · **Posted:** Sun Jun 26, 2011 9:08 am

Would this work?
http://store.europarts-sd.com/injectorr ... t-1-1.aspx

racertracer · **Posted:** Sun Jun 26, 2011 11:01 am

Gteat find wobbly

alphred · **Posted:** Sun Jun 26, 2011 12:15 pm

What about this technic:

http://www.instructables.com/id/How-to- ... low-Plugs/

Steel dont know what to do.
I know a stealer, who says that is diesel mechanic is able to remove the glow plug without removing the head of engine. But at 110$can/hr. I dont know if the dealer would accept to install the new GP 11v from europe ???

racertracer · **Posted:** Sun Jun 26, 2011 12:49 pm

Here's an intense stuck glow plug removal procedure on YouTube:

http://www.youtube.com/watch?v=koghDoROFko

Here is another home made device:

http://www.youtube.com/watch?v=kQ4DnWPe ... re=related

alphred · **Posted:** Sun Jun 26, 2011 1:29 pm

Thanks all of you !

is that it's very difficult to remove the egr valve ?

Wobbly · **Posted:** Sun Jun 26, 2011 2:20 pm

alphred wrote:

Thanks all of you !

is that it's very difficult to remove the egr valve ?

Yes, it's difficult. Even draining the radiator on the CRD is not easy without the right tool. The fuel filter head, battery tray, and hose from the CAC need to be removed to get at the EGR valve. The FCV and elbow should also be removed. The exhaust tube to the EGR valve also needs to be disconnected. The cooling lines to the EGR cooler need to come off. They may need to be cut off and replaced with new hose. The electrical connector for the EGR solenoid takes some fiddling to get off. There are some other hoses and lines which need to be tied off or loosened to get access.

racertracer · **Posted:** Sun Jun 26, 2011 3:09 pm

Sounds like a five minute job :jester:

alphred · **Posted:** Mon Jun 27, 2011 12:54 am

I would like to know if I can use the kj whit the broken GP in the old ?

Wobbly · **Posted:** Mon Jun 27, 2011 1:42 am

alphred wrote:

I would like to know if I can use the kj whit the broken GP in the old ?

Do you mean with the broken glow plug tip inside the cylinder?
Here a picture that supposedly shows the damage resulting to a different engine from a broken glow plug tip:
http://members.shaw.ca/k2pilot/Large%20 ... culate.jpg

Here is a article about damaged glow plugs. Not sure how much applies to the CRD:
http://members.shaw.ca/k2pilot/Glow%20p ... ticle.html

camo · **Posted:** Mon Jun 27, 2011 11:12 pm

Wow, I just had that problem 3 weeks ago but with GP#3 which is a lot more difficult to work with. anyway, I use a homemade extractor to get it out it paid off after many hours of enduring non fun work.
the main Idea is to drill out the threads of the old GP, and make a new thread inside the old GP so you can screw in a bolt, secure it and slide a 1/2" steel spacer through it with some washers and a nut to extract the old GP.
This link shows you how it is done on a Mercedes diesel engine that is prompt to this kind of problem. http://www.instructables.com/id/How-to- ... low-Plugs/ there are some few changes that you have to make though, but is the same basic process.
Just pray before you start and be armed with lots of patience.
I have some pics of my stuff I can email you if you email me.
Take care and God bless.
:frankie:

camo · **Posted:** Mon Jun 27, 2011 11:32 pm

here is what you need
1. 29/64 drill bit to destroy the old GP thread ( make sure you drill straight), and a tungsten carbide dremel bit to finish the corners the bit can't.
2. vacuum cleaner to suck any debris, and a good strong paper clip to remove the leftovers of the old GP thread from the head threads.
3. two taps M7-1.0 to thread the inside of the old GP and M10-1.0 for when the old GP is out repair any head thread that might have been damage.
4. M7 bolt or threaded rod to screw in to the newly created thread of the GP.
5.1/2" steel spacer to give clearance to the exiting GP
6.3 1/2" steel washers to put on top of the steel spacer
7.1 or 2 M7 nuts to put on the bolt or threaded rod to pull the GP
8.a vise grip to hold the bolt/threaded rod from the end while tightening the nut.
9.Permatex Hylomar to apply to the new plug on the threads and the GP body to prevent carbon build up and seize of the new GP threads (I put it on all 4 new GPs :wink:

)
Don't rush just pray and be patient.
I got all the stuff at a local ace hardware.
good luck

Wobbly · **Posted:** Tue Jun 28, 2011 9:17 am

Won't the broken glow plug tip damage the valves, pistons, liners, or the turbo if it isn't removed prior to running the engine?

camo · **Posted:** Tue Jun 28, 2011 4:16 pm

Yes, but on that type of breakage only the head of the GP and its core comes off leaving behind the housing and the tip due to carbon build up around the housing. So, if you can extract the GP body the tip will still be on the GP housing unless it had already broken before like it had happened to some of us, but that would b a different story. Anyway that was how I got my head broken GP off the cylinder head and saved some 1000+ on parts and labor for its removal.

camo · **Posted:** Tue Jun 28, 2011 7:23 pm

alphred wrote:

I tried to take out glow plug no 2. The GB have boken near the tread...

[img][img]http://nsa27.casimages.com/img/2011/06/26/mini_110626074453902583.jpg[/img][/img]

Can i use a «turne left tool» ?

I hope to find a other solution than taking of the head !!!

If your extractor brakes inside the old GP you will be in big trouble, what ever you do, dont use a left handed extractor, I might or might not get it out but if it brakes in there, then even a machine shop might not be able to get it out.

racertracer · **Posted:** Tue Jun 28, 2011 7:49 pm

What about turning the engine over for a second and blowing the stuck plug into a bucket filled with kevlar or some other material while standing back about 100 yards?

Pros and cons?

camo · **Posted:** Tue Jun 28, 2011 8:56 pm

a friend of mine with a Mercedes diesel only broke the thread of the GP and left it like that, about two weeks later the GP popped out due to the compression from the combustion chamber, it ripped the harness only but and a metallic part of the engine so it didn't cause further damage. however, he was stranded on the road and had to pay a wrecker to get back home. Still, a lot cheaper than removing the head.
:BANANA:

Help need !!Broken glow plug ! What to do ?

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