1996 E300D Glow Plug replacement

Hi,
I have a '96 E300D with at least one bad glow plug. (I used an ohm meter to test resistance on all 6 via the GP relay & found 1 to be completely open)
Since it is such a big job to replace the glow plugs, I plan to replace them all. My question is, when I remove the intake manifold, will I need to replace any gaskets, or should I be able to just bolt it right back together ? I would just like to have all the parts on hand prior to starting the job. Also, is there anything special or tricky I should know about this job ? (e.g. any special tools required, gotchas, etc)
Thanks in advance,
Brian
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Yes, you need new intake manifold gasket. Reasonably priced at the dealer.
Gotcha is depending on the mileage of your car, you might consider changing all the fuel lines while you are at it... which is what I did... especially the two rubber lines coming from and going to gas tank.
The EGR system... depending on the mileage you got on your car, you might want to change all the rubber parts as they do get brittle... no need to change those plastic lines... those are extremely expensive.
Get the right torx bit set for your socket wrench... and a proper in/ft torque wrench will prevent you from stripping those torx heads.
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Thanks for the info...I am in the process of removing the Intake manifold cross pipe.....I have removed the outside bolt on the intake manifold side, but am assuming there is an inside bolt, which I cannot see...how do I get to that bolt to remove it ?
Thanks in advance,
Brian Tiger wrote:

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There is only one bolt holding that cross over intake at the intake manifold side. This thing is a bit tricky to pull out. At the bolt, there is another inside sleeve so you have to pull it out at the other side.
The other side (air box side), you have to remove the bracket to slide out that inake crossover.
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Thanks, I got it out, removed & replaced 5 of 6 glow plugs, then, on the last one, the top sheared off as I was attempting to removed it :-( (i had applied penantrant oil previously).
I have now drilled out & placed an easy out in the glow plug, however I can't seem to turn it:-( Any recommendations on attempting to get this thing out short of removing the head ?
Thanks in advance,
Brian Tiger wrote:

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Mmm.... I don't have any suggestion if you are already using easy out... Mine were supposedly original but came out super easy. Drill the hole bigger and try easy out again.
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Hi,
I was unable to get the glow plug out after days of trying :-( So I took the car to a mercedes mechanic. He was unable to get it out as well so he had to remove the head & take it to a machine shop for removal. They were able to get the top of the glow plug out (the part with the threads) but were not able to get the bottom part out.
What I never realized was the bottom of the glow plug is, apparently, inaccessible even with the head off :-( So, does anyone out there have a recommendation on how to get the rest of the glow plug out ? I am hoping and praying that I will not have to replace the entire head because of this.
Your help is appreciated !!
Brian
Tiger wrote:

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????? strange. It can't be sifnificantly different than my 240D. the plugs came out normally. If, as you say, you got the 'threaded' part out, then there is no more, the carbon rod is inside the outer threaded metal/ceramic housing.... also, if you mechanic took 'one' of the plugs out, why not the rest of them when the head was off??? strange
cheers, guenter

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Guenter Scholz wrote:

Sorry, this was part of another thread that, apparently is long gone now. What happened was I was performing the routine maintenance of replacing the glow plugs on my E300D. 5 came out easily...the 6th, unfortunately didn't and the head bolt sheared right off. I tried heating, cooling, penetrating oil, bolt extractors, etc, but could not get the last glow plug out. That is why the car ended up at a mechanic.
He thought he might have a chance to get it out w/o removing the head but that did not work. The machine shop got the top part out, but on this model MBZ there is nearly 1 1/2- 2 inches more glow plug past the threads. This is the part that the machine shop could not get out.
What I am hoping is that there may be a way to extract it using chemicals to disolve it or something. As there is no access from the bottom side :-(
Thanks,
Brian

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