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Redrill glow plug - AR15.20-P-4112-01OG

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MODIFICATION NOTES

9.4.10 Value changed: bolt, cylinder head cover on cylinder head *BA01.20-P-1001-01P 
CRANKCASE VENTILATION, CYLINDER HEAD COVER

Number Designation Engine 642
BA01.20-P-1001-01P Bolt, cylinder head cover to cylinder head Stage 1, apply Nm 4
Stage 2, initial torque Nm 6
Stage 3, final torque Nm 9
PREGLOW SYSTEM

Number Designation Engine 642
BA15.20-P-1001-01F Glow plug on cylinder head M8 Nm 11
M10 Nm 18
Fig 1: Identifying Glow Plug Repair Kit, M8 (642 589 00 99 00)
G07253158Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Glow Plug Repair Kit Components
G07253159Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

NOTES In order to avoid damage to engine, the chips produced must be suctioned off immediately after every metal-cutting workstep and the bores must be cleaned with the pipe brush from the SPECIAL TOOL glow plug repair kit. Safety glasses should be worn.

  1. Place a 4 mm dia. stud extractor (1) on the pin of the glow pin cap and tear off center electrode of the glow plug (R9) clockwise.

    IMPORTANT Remove all loose and released parts.

    Fig 3: Tearing Off Center Electrode Of Glow Plug
    G07253160Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    IMPORTANT If the center electrode does not break at the lower end but instead immediately behind the cap of the electrical connection then the center electrode must be torn off again using the 4 mm dia. stud extractor (1). A drilling-out sleeve (2) must be hammered in if this is not possible in order to stabilize the center electrode during drilling-out.

  2. Hammer drilling-out sleeve (2) using a hammer.
    Fig 4: Hammering Drilling-Out Sleeve
    G07253161Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  3. Remove bolts (3) on the respective cylinder head cover of the broken off glow plug.
    Fig 5: Identifying Cylinder Head Cover Bolts
    G07253162Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  4. Place combined drilling and extraction device (4) with the fitted mounting bolts (5) finger-tight on the valve cover.
    Fig 6: Placing Drilling And Extraction Device On Valve Cover
    G07253163Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. Push centering and support pipe (6) with the thin diameter from through the guide adapter (7) and attach to the combined drilling and extraction device (4). Place guide adapter (7) at the end stop on the bolt.
  6. Align combined drilling and extraction device (4) in such a way that the centering and support pipe (6) is easy to move in the row of the glow pin.
  7. Tighten fitted mounting bolts (5) with a torque TORQUE SPECIFICATION on cylinder head cover.
  8. Remove centering and support pipe (6) again and subsequently attach the guide adapter (7) again to the combined drilling and extraction device (4).
    Fig 7: Attaching Guide Adapter To Combined Drilling And Extraction Device
    G07253164Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  9. Use special drill with gradation (8) to drill out the glow pin by 2 to 3 mm.

    IMPORTANT Only perform steps  11 through  13 if a drilling-out sleeve (2) was hammered in.

  10. Replace special drill with gradation (8) by the 4.5 mm dia. special drill (17) and drill out the center electrode of the glow pin down to the end stop of the drill holder (9).
    Fig 8: Drilling Center Electrode Of Glow Pin
    G07253165Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  11. Replace 4.5 mm dia. special drill (17) with the special drill with gradation (8) again.

    IMPORTANT Drilling and thread-cutting is required in two stages in order to avoid co-rotation of the glow pin during thread cutting.

  12. By putting down the special drill with gradation (8) a number of times drill the glow pin up to the marking (A) on the stem of the drill holder (9).
  13. Clamp thread tap UNF no. 12 (10) into thread tap holder (11) and, led through the combined drilling and extraction device (4), cut a thread in the glow plug as deeply as possible.

    IMPORTANT Work carefully with thread cutting and lubricate well.

    Fig 9: Identifying Guide Adapter, Drill Holder And Stem Marking
    G07253166Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  14. Bring special drill with gradation (8) again through the combined drilling and extraction device (4) into the slot and drill out the glow plug down to the end stop for the drill holder (9).
  15. Using thread tap UNF no. 12 (10) again led through the combined drilling and extraction device (4), cut the thread to the maximum possible depth in the glow plug.

    IMPORTANT Work carefully with thread cutting and lubricate well.

    Fig 10: Identifying Thread Tap Holder And Thread Tap
    G07253167Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  16. Lead extraction threaded spindle (12) through the combined drilling and extraction device (4) with a mounted guide adapter (7) and turn in the cut thread of the glow plug hole.
  17. Push centering and support pipe (6) over the extraction threaded spindle (12) and through the guide adapter (7).
    Fig 11: Identifying Extraction Threaded Spindle, Support Pipe, Mounted Guide Adapter And Extraction Device
    G07253168Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  18. Turn collar nut M8 with bearing cage (13) on the extraction threaded spindle (12) and pull out the remains of the glow pin. Always counterhold the extraction threaded spindle (12) at the hexagon.

    IMPORTANT If an increased force is necessary spray the glow pin with antiseize and lightly pound the extraction threaded spindle (12) under tension with a hammer on the hexagon.

    Fig 12: Turning Collar Nut M8 With Bearing Cage On Extraction Threaded Spindle
    G07253169Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  19. The now released glow pin bore should first be cleaned to be free of soot and deposits using the 7.0 mm dia. cylindrical pipe brush (18) and then with the 4.2 mm dia. cylindrical pipe brush (19).
    Fig 13: Cleaning Glow Pin Bore
    G07253170Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    IMPORTANT If there is no stop plug available to prevent ingress of chips into the cylinder compartment then the stop plug can be made, as described below, from a drilled out glow plug.

  20. Shorten removed glow pin residue (14) on the drilled out end by about 15 mm.
  21. Recut thread in the removed glow pin residue (14) and clean the stem.
  22. Introduce rest of the glow pin (14) into the clean glow pin shaft as a stop plug.
    Fig 14: Identifying Glow Pin Residue Drilled End
    G07253171Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 15: Inserting Stop Plug
    G07253172Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Dimensions: 

  23. Wet thread tap M8x1 (15) with grease and recut the thread cleaning in the cylinder head.
  24. Remove stop plugs using magnets or the extraction threaded spindle.
  25. Screw glow plug into cylinder head with torque TORQUE SPECIFICATION
    Fig 16: Identifying Thread Tap
    G07253173Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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