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Thread: Now I'm in the doo doo's

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    Default Now I'm in the doo doo's

    Changing the glow plugs today on my 2.2Dti, one of them sheared just below the nut that forms part of the body.
    Anyone know of a way to remove it without removing the head? I can't be the first person this has ever happened to.
    The other 3 came out as sweet as a nut, this damned one gave no indication of what was going to happen. Just stopped turning and sheared within 1/8 of a turn!
    Best case scenario I can see is remove the inlet manifold, turbo etc and see if I can hammer a torx bit into it to turn it out, worst case is head off.
    Any mechanics had this before?

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    Regular Member DennisTheMenace's Avatar
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    drill it out and tap it , problem being if bits drop into the combustion chamber

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    Regular Member Gsi3.2's Avatar
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    as dennis said.. BUT..don't try it with a standard drill bit.. a diesel fitter freind of mine used of all things a rewored masonary bit ( tips regound to remove the wings and to form a single cutting edge like an HSS bit) as the glowplug is going toi be dead hard..don't go 'size' either, go slighlty under ( say 3mm lees) to allow for a bit of 'wander' in the drilland watch how deep you're drilling..then you should be able to fold the remains in on itself and withdraw it without dropping any swarf into the cylinder.. if it does need tapping, pack the flutes of the tap with grease to hold the swarf and clean and repack the flutes regularly..

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    Regular Member Gsi3.2's Avatar
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    oh, and don't hammer a torx bit into it.. if that shatters then it won't be possible to drill it out at all..then you're looking at spark erosion to get it out at £££££££

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    before you try that run a drill in reverse pressed against it, sometimes the reverse action can shift snapped bolts even if they sheared when unfastening just from the vibration and reverse action. Lubricate round it with wd40 or similar then give it a go for about a minute. Worked for me on several snapped items over the years. Next I would try stud extractors - reverse thread screws that screw into a hole you drill then the tighter they get the more pressure they put to undo the stuck thread. Must have happened to someone before, probably on spark plugs given the shear number of removals. Ive never changed glow plugs being a fairly recent convert to the oil burners, best of luck - hope this helps.

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    I'll have to remove the manifold and turbo anyway I think to make access a little easier.
    Had to be on the "back" side of the engine didn't it, just to make things harder. I think I'll start by soaking it in PlusGas overnight then trying a easyout extractor gently. I'm a little worried by it snapping as well but hopefully the PlusGas will help with this.
    Failing that then I'll try drilling it out carefully. I'm going to speak to a diesel fitter friend of mine today for some advice, if he thinks it's easier to take the head off we'll do that as he can point me in the right direction whilst he carries on with his own work.
    I could use mole grips to screw it through the head in reverse then as I would have a decent sized body to clamp on it.
    Will let you know how we eventually do it. The car is running fine at the moment as it is so I'll probably have a go at it this weekend.

  7. #7
    Regular Member Gsi3.2's Avatar
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    beware of 'easyouts' as they cause more problems than they solve..if they snap then it's spark eroding again for you....

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    Thanks for the warning GSI, I'll bear that in mind.

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    Regular Member sophos9's Avatar
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    Cannot add anything here apart from fingers crossed mate, what a mare hey.... How long between service intervals on plugs?

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    Default

    normally when they pack up in my case.. I had one and the thing just kept spinning in the head. luckily enough the car got written off before i had to do anything about it

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