I was over at JHunt's yesterday evening and he was finishing up the last of the glowplugs on his '95 E300. Many of them were stuck and he's come up with an innovative solution to remove them using hydraulics without removing the head. I thought is was really slick... Literally!

Here's a few pictures of the process:

First the pre-chamber ring is removed:

http://i3.photobucket.com/albums/y71...l/SANY0442.jpg

http://i3.photobucket.com/albums/y71...l/SANY0443.jpg

Next, the pre-chamber puller is installed:

http://i3.photobucket.com/albums/y71...l/SANY0435.jpg

http://i3.photobucket.com/albums/y71...l/SANY0438.jpg

The original design puller makes it easy to crank them out:

http://i3.photobucket.com/albums/y71...l/SANY0440.jpg

http://i3.photobucket.com/albums/y71...l/SANY0441.jpg

Next, the pre-chamber pocket in the head is plugged with this Delryn plug and honed a few seconds with a brake cylinder hone to ensure a smooth finish and seal:

http://i3.photobucket.com/albums/y71...l/SANY0451.jpg

http://i3.photobucket.com/albums/y71...l/SANY0449.jpg

The custom made hydraulic fitting is then inserted into the head:

http://i3.photobucket.com/albums/y71...l/SANY0436.jpg

http://i3.photobucket.com/albums/y71...l/SANY0446.jpg

The pressure is pumped up to around 2000 PSI with a modified injector pop tester filled with oil.

http://i3.photobucket.com/albums/y71...l/SANY0447.jpg

After a turn of the glowplug, it slides right out!

http://i3.photobucket.com/albums/y71...l/SANY0448.jpg

The tool can also be pumped up and left for a period of time and the glowplugs will literally push out by themselves.

Good job on tool fabrication.

Doesn't the tip of the glow plug get sheared off when the prechamber is extracted? I'd be a little concerned about possible damage to the head...

:nuke:

This would only work if all the threads of the plug are out and the shaft is stuck.

You'd know by a free spinning glow plug?

Sixto
87 300D

Dimensions please
 

I would appreciate the dimensions of the Pre-chamber puller box, and custom made hydraulic fitting.


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little help with this please
 

I should know this, but, don't the valves have to all be closed for this to work? Is 2000 psi of fluid enough to move the piston? How do you remove the hydraulic fluid from the cylinder? Rags? Q-tips?

Also, where does the person who came up with this set up live? What do you think he would charge for this job? 4 of my 6 glow plugs are stuck, but at least I can get the threads clear.

Wild guess here, but based on the design of the tool, I think the liquid is retained inside the head and all forced out the glow plug hole. I don't think any liquid will enter the combustion chamber at all. Right...?

:boat:

From the looks of things the hydraulic fluid when in action is only in the space between the upper and lower o-ring type seals on the tool head when it's placed in the prechamber bore and any space near the sheared of glow plug's bore. Although it isn't shown I suspect there is no fluid exiting the bottom area of the tool head and getting into the combustion cylinder area, well maybe a few drops or drips but none of the working fluid does.

It is a pretty clever solution to a very real problem on these engines, like gsxr I would be concerned about possible damage to the prechamber bore as it is aluminum. The prechamber acts as one side of the "shear" with the aluminum head acting as the opposite side.

This stuck glow plugg issue is wide spread and pretty expensive to remedy. The KLANN Tools solution of deconstructiong the glow plug piece by piece is another pretty clever solution, but as to be expected the tool price is difficult to justify for most individuals. Good luck with your engine.

"...hydraulic fluid when in action is only in the space between the upper and lower o-ring type seals on the tool head..."

Yes. Now I see. Thanks.

I think that the Klann tool is designed for use on the 606 in the 210. Would like to hear if that is accurate.

This tool is used if the plug becomes jammed after first unscrewing past the pre-chamber.

Roy, which dimensions would you like?

I don't have specific literature at hand but I'm pretty sure that the prechamber/glow plug arrangement is quite similar between the DOHC 605 and the 606 cylinder heads no?

Answer
 

Pictures attached

when I've had them break (twice now), they have typically broken off before being unthreaded from the head. Only solution was to C A R E F U L L Y drill them out.

Pretty sure that has been the way they're broken off for most people.

Impressive machining, just the same

606 Glow Plug Removal
 

What do you all think of ; Remove all injectors , unplug all glow plugs , liberally apply wd-40 , remove fuel filter , crank- repeat ,. crank , get wd in behind glow plug , then remove ?