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

Engine 642 

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 Nm 9
Phosphated Nm Nm 9
10.9 Galvanized Nm Nm 13
Phosphated Nm Nm 12
12.9 Galvanized Nm Nm 16
Phosphated Nm Nm 14
Fig 1: Identifying Glow Plug Repair Set (642 589 01 99 00)
G10120134Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Glow Plug Repair Kit, M8 (642 589 00 99 00)
G09975074Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Record Plug (611 589 00 91 00)
G09975131Courtesy 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 set 642 589 00 99 00 

G14134386Courtesy of MERCEDES-BENZ USA

Shown: glow plug repair set 642 589 01 99 00 

G14134387Courtesy of MERCEDES-BENZ USA

IMPORTANT Use the following special tool: SPECIAL TOOL Glow plug repair kit, M8 642 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.

    G07253160Courtesy of MERCEDES-BENZ USA
    G07253161Courtesy of MERCEDES-BENZ USA
  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

    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.

    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

    ↓

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

    Attach and align the boring out jig 

  3. Remove screw/bolts (3) of the cylinder head cover in the area of the broken off glow plug.
    G07253162Courtesy of MERCEDES-BENZ USA
  4. Mount combined drilling and extraction device (4) with fit bolts (5) on the cylinder head cover.
    G07253163Courtesy of MERCEDES-BENZ USA
  5. Lead the centering and support pipe (6) with the thinner diameter from below into the bayonet guide (7).
    G11972911Courtesy of MERCEDES-BENZ USA
  6. Attach the bayonet guide (7) with the centering and support pipe (6) to the combined drilling and extraction device (4) and tighten the screw/bolt (4a) TORQUE SPECIFICATION
  7. Push the centering and support pipe (6) into the glow plug well and center it.

    IMPORTANT Through turning the combined drilling and extraction device (4) center the centering and support pipe (6) in such a way that it is aligned with the glow plug.

  8. Tighten fit bolts (5) TORQUE SPECIFICATION

    IMPORTANT After tightening the fit bolts (5) 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.

  9. Detach bayonet guide (7) from the combined drilling and extraction device (4) and remove centering and support pipe (6).
  10. Mount the bayonet guide (7) on the combined drilling and extraction device (4).
    G11972912Courtesy of MERCEDES-BENZ USA

    Redrill glow plug 

  11. Clamp the graduated drill (8) into the drill holder (9) and lubricate the graduated drill (8) as well as the drill holder (9).

    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.

    G11972913Courtesy of MERCEDES-BENZ USA
  12. Introduce the drill holder (9) with graduated drill (8) into the bayonet guide (7) and position and center glow plug 2 to 3 mm deep.

    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.

    G07253165Courtesy of MERCEDES-BENZ USA
  13. Clamp the special drill (17) into the drill holder (9) and lubricate the special drill (17) as well as the drill holder (9).

    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.

  14. Drill out the center electrode of the glow plug until the drill holder (9) almost touches the cylinder head.

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

    G11972915Courtesy of MERCEDES-BENZ USA
  15. Clamp the graduated drill (8) into the drill holder (9) and lubricate the graduated drill (8) as well as the drill holder (9).

    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.

    G11972913Courtesy of MERCEDES-BENZ USA
  16. Introduce the drill holder (9) with graduated drill (8) into the bayonet guide (7) and drill out the glow plug thread at the core up to the marking (A).

    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 drill holder (9) reaches the upper edge of the bayonet guide (7).

  17. Pull the drill holder (9) with a graduated drill (8) out of the bayonet guide (7).
  18. Clean opening.
    G07253166Courtesy of MERCEDES-BENZ USA
  19. Clamp the graduated drill (10) into the thread tap holder (11) and lubricate the graduated drill (10) as well as the thread tap holder (11).

    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".

    G07253167Courtesy of MERCEDES-BENZ USA
  20. Introduce the thread tap holder (11) with thread tap (10) into the bayonet guide (7).
  21. Mount the tool holder with ratchet (16) on thread tap holder (11) 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.

  22. Remove the thread tap (10) and pull out with thread tap holder (11) from the bayonet guide (7).
  23. Clean opening.
    G11972919Courtesy of MERCEDES-BENZ USA
  24. Lubricate the graduated drill (8) and the drill holder (9).

    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.

  25. Introduce the drill holder (9) with graduated drill (8) through the bayonet guide (7).
  26. 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 drill holder (9) almost stands on the cylinder head.

  27. Pull the drill holder (9) with a graduated drill (8) out of the bayonet guide (7).
  28. Clean opening.
    G07253165Courtesy of MERCEDES-BENZ USA
  29. Lubricate the thread tap (10) and the thread tap holder (11).

    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".

    G07253167Courtesy of MERCEDES-BENZ USA
  30. Introduce the thread tap holder (11) with thread tap (10) into the bayonet guide (7).
  31. 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.

  32. Remove the thread tap (10) and pull out with thread tap holder (11) from the bayonet guide (7).
  33. Clean opening.
    G11972919Courtesy of MERCEDES-BENZ USA
  34. Screw in the extraction spindle (12) through the bayonet guide (7) into the previously cut thread.

    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".

  35. Lead the centering and support pipe (6) with the thinner diameter from below into the bayonet guide (7) and glow plug well.
  36. Grease the extraction spindle (12).
    G07253168Courtesy of MERCEDES-BENZ USA
  37. Screw bearing unit (13) onto the extraction spindle (12).
  38. 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.

    IMPORTANT For very sluggish extraction processes of the bearing unit (13) loosen again and carefully tap the end of the extraction spindle (12) with a hammer.

    G07253169Courtesy of MERCEDES-BENZ USA
    G11972925Courtesy of MERCEDES-BENZ USA
  39. Clean glow plug hole with round wire brushes (18, 19) free of soot and deposits.
    G07253170Courtesy of MERCEDES-BENZ USA

    Recut the glow plug thread in the cylinder head 

  40. Insert a grommet from the SPECIAL TOOL set of stop plug in the glow plug hole.
  41. Clamp the thread tap (15) into the thread tap holder (11) 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.

    G11972927Courtesy of MERCEDES-BENZ USA
  42. Introduce the thread tap holder (11) with thread tap (15) into the bayonet guide (7).
  43. Recut the fastening thread of the glow plug in the cylinder head clean.
  44. Remove the thread tap holder (11) with thread tap (15) from the bayonet guide (7).
  45. Clean the fastening thread of the glow plug in the cylinder head and the glow plug hole.
  46. 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

  47. Remove the grommet from the glow plug hole.
    G11972928Courtesy of MERCEDES-BENZ USA

    Remove the boring out jig 

  48. Detach the bayonet guide (7) from the combined drilling and extraction device (4).
  49. Remove fit bolts (5) and remove the combined drilling and extraction device (4).
    G07253163Courtesy of MERCEDES-BENZ USA
  50. Fully tighten screw/bolts (3) TORQUE SPECIFICATION
    G07253162Courtesy of MERCEDES-BENZ USA
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