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motorworks
Member Since: 14 Nov 2019
Location: Usk
Posts: 401
  
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I removed a D3 engine with failed turbo and glow plugs. Has done 200k miles, possibly still on original gp's. I managed to undo two with patience, but they were really tight and close to shearing. The other four snapped.
I used an extractor kit to drill out and remove threaded top section of the gp's, but no good to take out the remaining pieces. I was considering cylinder heads removal as the next move, but hardly worth the time and expense.
Yesterday, I drilled a remaining core, tapped a thread and attached a slide hammer using threaded bar. Using a lot of force, I was surprised to see the remaining piece come out. Repeated the process on two more but tip stayed in on one of them. I poured in some penetrating oil and left overnight.
Today, I ensured the valves were closed and blew compressed via the injector port and the tip came out easily. One remaining gp left to extract, but should be straightforward.
I wonder how often failed gp's have a loose tip, with risk of consequential damage. Chris
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 26th Jun 2021 10:31 pm |
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PCT3
Member Since: 13 May 2017
Location: Kent
Posts: 144
 
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Have never tried with a Modern diesel, but in the old days glow plug replacement was common, we also used to drill out the carbon build up that would be around the tip. As suggested we would have piston on tdc compression stroke remove plug drill out even if it didn’t break always a lot of carbon build up, long thin air blower, blast out the debris, was a common job but think the engines were a little less sensitive then
Whilst drilling always a lot of heavy grease to collect as much debris as possible Discovery 3 HSE 07
Discovery 1, Search & Rescue SE4x4 Responce
Fiat Decato motor home
Mazda MX5
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| 7th Jul 2021 8:02 am |
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Pete K
Member Since: 15 Jan 2016
Location: GL
Posts: 10361
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the tip will cause damage to the engine and turbo, so you need to get it out.
Take the head off if necessary
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| 7th Jul 2021 9:18 am |
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motorworks
Member Since: 14 Nov 2019
Location: Usk
Posts: 401
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Not enough thread left to hold even 10Nm (recommended torque) on two cylinders. I tried an insert kit, which provided a really neat and secure solution.
I have noticed that glow plugs are irrelevant in this weather. Cars start just as well when they are disconnected, or failed. As cold weather returns more will need replacing, or use FBH remote control.
If a TDV6 will not start because of failed gp's, likely three or more are broken. Is there a risk of engine damage with repeated lumpy and imbalanced starting? Chris
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| 3rd Aug 2021 10:00 pm |
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Pete K
Member Since: 15 Jan 2016
Location: GL
Posts: 10361
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Below 0C they are needed to start the engine.
FBH remote start on eBay aren’t expensive.
They should / may drop before winter
https://www.ebay.co.uk/itm/124117320536
Or the resistor trick will start it
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| 3rd Aug 2021 10:09 pm |
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