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Redrill Glow Plug - AR15.20-P-4112-01OLD

ENGINE 651 

HEADLESS SCREWS: BOLTS AND NUTS, COARSE-PITCH THREAD

Number Designation Model all (4xWD, CAR, smart)
BA00.10-P-1002-01A M6 8.8 Galvanized Nm 9
Phosphated Nm 9
10.9 Galvanized Nm 13
Phosphated Nm 12
12.9 Galvanized Nm 16
Phosphated Nm 14
G12081378Courtesy of MERCEDES-BENZ USA
G12081379Courtesy of MERCEDES-BENZ USA
G09975074Courtesy of MERCEDES-BENZ USA
G12081381Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1017-06A MB multipurpose grease, 400 g A 001 989 34 51 11
BR00.45-Z-1093-06A Multipurpose oil A 000 989 84 01

Shown: glow plug repair kit, M8 642 589 00 99 00 

G12081382

Shown: glow plug repair kit, M8 651 589 00 99 00 

G12081383

Shown: glow plug repair set 642 589 01 99 00 

G12081384

View of glow plug repair kit 651 589 00 99 00 

G12081385

IMPORTANT Use the following special tools: SPECIAL TOOL glow plug repair kit, M8 642 589 00 99 00 and SPECIAL TOOL glow plug repair kit, M8 651 589 00 99 00.

For a glow plug thread M10x1 also use: SPECIAL TOOL Glow plug repair set 642 589 01 99 00.

NOTES After every chip cutting machining operation step immediately suction up the chips created or clean the bores with a round wire brush (18, 19).

Damage may occur on the engine otherwise.

Prepare the glow plug 

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

    IMPORTANT Remove all loose parts.

    G07253160
  2. Again tear off the center electrode of the glow plug using the stud extractor (1) for a 2.5 mm dia.

    If the center electrode of the glow plug is broken not on the lower end but rather immediately behind the cap of the electrical connection.

    If renewed tearing off of the center electrode of the glow plug is not possible

    ↓

    Hammer in the drill-out sleeve (2) using a hammer and punch flush into the glow plug

    ↓

    Cut off the projecting out part of the drill-out sleeve (2) flush using a side cutting pliers

    NOTES The drill-out sleeve (2) is beveled; the arrow on the drill-out sleeve (2) must point to the cylinder head.

    Damage may occur otherwise on the cylinder head.

    IMPORTANT In order to stabilize the center electrode for drilling out.

    G07253161

    IMPORTANT For a glow plug thread M8x1 use a drill-out sleeve (2) with an inside diameter of 2.6 mm.

    For a glow plug thread M10x1 use a drill-out sleeve (2) with an inside diameter of 3 mm.

    If the drill-out sleeve (2) cannot be hammered in flush

    Attach and align the boring out jig 

  3. Mount the mounting rail (20) with mounting angles (21) and screw/bolts (22, 23) loosely on the cylinder head.

    IMPORTANT Use screw/bolts (23) for rail.

  4. Push mounting rail (20) downwards (arrows) and tighten screw/bolts (23) TORQUE SPECIFICATION .
    G12081388
  5. Lead the centering and support pipe (6) with the thinner diameter from below into the bayonet guide (7).

    When drilling out glow plug on cylinder 1, 2 or 3.

    G11972911
  6. Align centering and support pipe (6) with bayonet guide (7) over the glow plug to be drilled out at the mounting rail (20) and tighten screw/bolt (4a) TORQUE SPECIFICATION .

    When drilling out glow plug on cylinder 1, 2 or 3.

  7. Push the centering and support pipe (6) into the glow plug well (arrow) and center it.

    When drilling out glow plug on cylinder 1, 2 or 3.

    IMPORTANT Through turning the combined drilling and extraction device (20) center the centering and support pipe (6) in such a way that it is aligned with the glow plug.

    G12081390
  8. Tighten down screw/bolts (22) for the mounting rail (20) TORQUE SPECIFICATION .

    When drilling out glow plugs on cylinder 1, 2 or 3.

    IMPORTANT After tightening the screw/bolts (22) the centering and support pipe (6) it must still be possible to introduce it into the glow plug well and to pull it out again without special use of force. If not, repeat the centering process.

    G12081391
  9. Detach bayonet guide (7) from the mounting rail (20) and remove the centering and support pipe (6).

    When drilling out the glow plug at cylinder 1, 2 or 3.

  10. Mount bayonet guide (7) on mounting rail (20) and tighten the screw/bolt (4a) TORQUE SPECIFICATION .
    G12081390
  11. Introduce the combination bracket (24) through the bayonet guide (7) into the glow plug well.

    For drilling out the glow plug on cylinder 4.

    IMPORTANT The inscription IN/OUT POSITION on the combination bracket (24) must point upwards.

  12. Center the combination bracket (24) in the glow plug well (arrow).

    For drilling out the glow plug on cylinder 4.

    IMPORTANT Through shifting of the mounting rail (20) center the combination bracket (24) in the bayonet guide (7) in such a way that it is aligned to the glow plug.

  13. Tighten down both screw/bolts (22) for the mounting rail (20) TORQUE SPECIFICATION .

    For drilling out the glow plug on cylinder 4.

    IMPORTANT After tightening the screw/bolts (22) it must still be possible to introduce the combination bracket (24) into the glow plug well and to pull it out again without special use of force. If not, repeat the centering process.

    G12081393

    Redrill glow plug 

  14. Clamp the graduated drill (8) into the combination bracket (24) and lubricate the graduated drill (8) as well as the combination bracket (24).

    IMPORTANT For a glow plug thread M8x1 use the graduated drill (8) with an inscription M8.

    For a glow plug thread M10x1 use the graduated drill (8) with an inscription M10.

    G12081394
  15. Introduce the combination bracket (24) with graduated drill (8) into the bayonet guide (7).

    IMPORTANT For a glow plug thread M8x1 use the graduated drill (8) with an inscription M8.

    For a glow plug thread M10x1 use the graduated drill (8) with an inscription M10.

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (24) must point upwards.

  16. Center and position glow plug 2 to 3 mm deep.

    If a drill-out sleeve (2) was previously stamped in.

    G12081395
  17. Clamp the special drill (17) into the combination bracket (24) and lubricate the special drill (17) as well as the combination bracket (24).

    If a drill-out sleeve (2) was previously stamped in.

    IMPORTANT For a glow plug thread M8x1 use the special drill (17) with a 4.5 mm dia. For a glow plug thread M10x1 use the special drill (17) with a 5.5 mm dia.

  18. Drill out the center electrode of the glow plug until the combination bracket (24) almost touches the cylinder head.

    If a drill-out sleeve (2) was previously stamped in.

    G12081396
  19. Clamp the graduated drill (8) into the combination bracket (24) and lubricate the graduated drill (8) as well as the combination bracket (24).

    If a drill-out sleeve (2) was previously stamped in.

    IMPORTANT For a glow plug thread M8x1 use the graduated drill (8) with an inscription M8.

    For a glow plug thread M10x1 use the graduated drill (8) with an inscription M10.

    G12081394
  20. Introduce the combination bracket (24) with graduated drill (8) into the bayonet guide (7).

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (24) must point upwards.

  21. Drill out the glow plug thread in the core up to the marking 1st STOP OM651.

    IMPORTANT Through multiple putting down of the graduated drill (8) bore out the glow plug thread at the core until the marking (A) on the combination bracket (24) 1st STOP OM651reaches the upper edge of the bayonet guide (7).

  22. Remove the combination bracket (24) with graduated drill (8) from the bayonet guide (7).

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (24) must point upwards.

  23. Clean opening.
    G12081398
  24. Clamp the thread tap (10) into the combination bracket (25) and lubricate the thread tap (10) as well as the combination bracket (25).

    IMPORTANT For a glow plug thread M8x1 use the thread tap (10) with the inscription UNF No. 12.

    For a glow plug thread M10x1 use the thread tap (10) with the inscription UNF 1/4".

    G12081399
  25. Introduce the combination bracket (25) with thread tap (10) into the bayonet guide (7).

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (25) must point upwards.

  26. Mount the tool holder with ratchet (16) on combination bracket (25) and cut a thread in the glow plug body.

    IMPORTANT Cut the thread as a right-hand thread as deep as possible into the glow plug body. Lubricate the thread tap (10) a number of times in the process.

  27. Remove the thread tap (10) with combination bracket (25) from the bayonet guide (7).

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (25) must point upwards.

  28. Clean opening.
    G12081400
  29. Lubricate the combination bracket (24) and the graduated drill (8).
  30. Introduce the combination bracket (24) with graduated drill (8) into the bayonet guide (7).

    IMPORTANT For a glow plug thread M8x1 use the graduated drill (8) with an inscription M8.

    For a glow plug thread M10x1 use the graduated drill (8) with an inscription M10.

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (24) must point upwards.

  31. Bore out the remaining glow plug thread.

    IMPORTANT Through multiple application (putting down) of the graduated drill (8) bore out the glow plug thread until the combination bracket (24) almost stands on the cylinder head.

  32. Remove the combination bracket (24) with graduated drill (8) from the bayonet guide (7).

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (24) must point upwards.

  33. Clean opening.
    G12081395
  34. Introduce the combination bracket (25) with thread tap (10) into the bayonet guide (7).

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (25) must point upwards.

  35. Cut the thread further into the glow plug holder.

    IMPORTANT Cut the thread as a right-hand thread as deep as possible into the glow plug body. Lubricate the thread tap (10) a number of times in the process.

  36. Remove the thread tap (10) with combination bracket (25) from the bayonet guide (7).

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (25) must point upwards.

  37. Clean opening.
    G12081400
  38. Remove screw/bolt (4a) and detach bayonet guide (7) from the mounting rail (20).
    G12081403
  39. Introduce the centering and support pipe (6) with the thicker end into the glow plug well.
  40. Screw extraction spindle (12) into the previously cut thread and tighten.

    IMPORTANT For a glow plug thread M8x1 use the extraction spindle (12) with thread UNF No. 12.

    For a glow plug thread M10x1 use the extraction spindle (12) with thread UNF 1/4".

  41. Grease the extraction spindle (12).
    G12081404
  42. Screw bearing unit (13) onto the extraction spindle (12).
    G12081405
  43. Counterhold the extraction spindle (12) and remove the remains of the glow plug (14) by turning the bearing unit (13).

    NOTES Always counterhold the extraction spindle (12) by turning the bearing unit (13)! Damage may occur otherwise on the cylinder head.

    If the extraction is very sluggish:

    ↓

    Loosen the bearing unit (13) again and carefully tap the end of the extraction spindle (12) with a hammer.

    G12081406
    G11972925
  44. Clean glow plug hole with round wire brushes (18, 19) free of soot and deposits.

    IMPORTANT For a glow plug thread M8x1 use the round wire brushes (18, 19) with a 7 mm dia. and a 4.2 mm dia.

    For a glow plug thread M10x1 use the round wire brushes (18, 19) with a 8.5 mm dia. and a 5.3 mm dia.

    G07253170

    Recut the glow plug thread in the cylinder head 

  45. Insert a grommet from the SPECIAL TOOL set of stop plug in the glow plug hole.
  46. Mount bayonet guide (7) with screw/bolt (4a) on mounting rail (20) over the glow plug hole TORQUE SPECIFICATION .
    G12081403
  47. Clamp the thread tap (15) into the combination bracket (25) and fill the flutes of the thread tap (15) with grease.

    IMPORTANT For glow plug thread M8x1 use the thread tap (15) with an inscription M8x1.

    For glow plug thread M10x1 use the thread tap (15) with an inscription M10x1.

  48. Introduce the combination bracket (25) with thread tap (15) into the bayonet guide (7).

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (25) must point upwards.

    G12081410
  49. Mount the tool holder with ratchet (16) on the combination bracket (25) and recut the fastening thread of the glow plug in the cylinder head clean.
  50. Remove the combination bracket (25) from the bayonet guide (7).

    IMPORTANT On cylinder 4 the inscription IN/OUT POSITION on the combination bracket (25) must point upwards.

  51. Clean the fastening thread of the glow plug in the cylinder head and the glow plug hole.
  52. Check the fastening thread of the glow plug in the cylinder head for damage.

    If the glow plug thread is damaged

    ↓

    Repair the glow plug thread using the thread repair set

  53. Remove the grommet from the glow plug hole.
    G12081400

    Remove the boring out jig 

  54. Detach bayonet guide (7) from mounting rail (20).
  55. Remove screw/bolts (23) and detach mounting rail (20) with mounting angles (21) from cylinder head.
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