Glowplug stripped out of casing - Defender Source
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  #1  
Old March 16th, 2013, 02:34 PM
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Glowplug stripped out of casing

I'm in the DR fixing up a 300tdi. Went to replace the glow plugs and the top broke off one and the casing came out without the glow tip.

Any suggestions to get it out? Tried pulling and nothing. Pushing, noting. I think massive carbon build up has resulted it in being stuck in there. Tried prying and nothing.
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  #2  
Old March 16th, 2013, 02:38 PM
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Not what you want to hear or do, but you'll have to pull the head.
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  #3  
Old March 16th, 2013, 02:42 PM
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Spray a bunch of PBBlaster, WD40, etc, soaking the thread area as much as possible. Then just drive around till it liberates itself. Keep a new plug and a socket handy to install it when the stuck one dislodges itself.
Good read below:
Snapped Glow Plug
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Old March 16th, 2013, 03:22 PM
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Off with the head!!!!!!!!!

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Originally Posted by Wolf Fabrication View Post
Not what you want to hear or do, but you'll have to pull the head.
Yeah... what he said.
Our machine shop had to make a special punch to drive our stuck glow plugs out.
Sort of a punch with the tip indented to accept the glow plug tip profile.

Read up on the head torque sequence before you reassemble as it is a 4 step process.
Pendy walked me through my first time years ago... what a great guy.
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Old March 16th, 2013, 04:08 PM
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If all the threaded part came out and the tip is stuck in there, drive it. The heat/cool cycle will loosen it and the cylinder pressure will pop it out. Try to stop as soon as it pops and put in a new one to prevent the threads being damaged from the flow of gas.
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Old March 16th, 2013, 04:26 PM
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Drive it till it pops out is one of the worst ideas I have heard.

Lets say it dislodges, doesnt "pop" out, but falls back down into the cylinder? Now youre out a block, head, and piston.

Do it once, the right way. Take off the head and have it removed at a machine shop. Or work it a little more where it is with a slide hammer and some PB blaster and/or light heat.
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Old March 16th, 2013, 07:48 PM
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Thanks guys. Man this is going to suck. Julian, if you read this thread give me a call. I want to know where you can get a 3 hole head gasket and bolt set here in the DR.
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Old March 16th, 2013, 09:06 PM
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Quote:
Originally Posted by ini88 View Post
Thanks guys. Man this is going to suck. Julian, if you read this thread give me a call. I want to know where you can get a 3 hole head gasket and bolt set here in the DR.
I may have both here at my place...if you need me to mail them to you, I can be talked into it. Let me know.
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  #9  
Old March 16th, 2013, 09:44 PM
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Quote:
Originally Posted by transientmechanic View Post
Drive it till it pops out is one of the worst ideas I have heard.

Lets say it dislodges, doesnt "pop" out, but falls back down into the cylinder? Now youre out a block, head, and piston.

Do it once, the right way. Take off the head and have it removed at a machine shop. Or work it a little more where it is with a slide hammer and some PB blaster and/or light heat.
It won't fall in. There is no suction and only pressure. I've done this before on TDIs and it always works. The plugs break quite easily and they are usually quite stuck. They just pop right out once the head heats up a bit.
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Old March 16th, 2013, 11:22 PM
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The truck will not start which I find a bit strange seeing as its 90 degrees here. I guess it does need the plugs.

So I may tow it with my shitty Kai rental and hopefully pop start it and let it run for a bit and maybe see if the plugs pop out. I have them soaking in WD40 right now where they are.

If not, heads coming off and I'll have to come back down or see if my uncle can do it himself after I send him the parts.
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Old March 16th, 2013, 11:34 PM
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Daniel,
Do you have all the glow plugs out? If so, it won't start due to the low compression. Screw them back in and it should fire up. My engine started up kind of smokey when 2 plugs failed and two were working.
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Old March 17th, 2013, 12:01 AM
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That blows dude. But what do you need glow plugs for in the dr. My 200tdi started in 4 degree weather in Maine with NO working glow plugs


You need them in to start, but my working. If it won't start with them in its something else
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Old March 17th, 2013, 02:14 AM
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I have never used my glow plugs once. Never had a problem starting in virginia winters. Sorry for the useless post
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Old March 17th, 2013, 09:09 AM
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That's what I was thinking too. I read the 300tdi doesn't need glow plugs to even start unless super cold out.

Could be the valves are way out of spec and not holding compression for an easy start.

It was starting before but it would be random and sometimes not start so I'm thinking the glow plugs were so caked in carbon that they weren't igniting the fuel. It would also smoke like hell on start up so I thought some of the glow plugs weren't working or caked up.

Heading out to rip the head off now. I'll try to find some wifi
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  #15  
Old March 17th, 2013, 12:01 PM
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How is the compression?
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Old March 17th, 2013, 01:03 PM
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Damiel,
I haven't had my glow plugs hooked up since Feb 2010. You shouldn't need them especially in Italy. I'd suspect the fuel shut off solenoid but crack an injector line and see if fuel is coming out as you turn the engine over. If not work backwards until you find out why.
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Old March 17th, 2013, 07:19 PM
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Quote:
Originally Posted by 130Tdi View Post
Damiel,
I haven't had my glow plugs hooked up since Feb 2010. You shouldn't need them especially in Italy. I'd suspect the fuel shut off solenoid but crack an injector line and see if fuel is coming out as you turn the engine over. If not work backwards until you find out why.
I know what you are saying. 90 degrees here in the Dominican Republic and I need glow plugs? That was our first task to getting this disco running be
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  #18  
Old March 17th, 2013, 07:26 PM
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I'm a little late to this party, but I had the exact same problem on my ill fated Alaska trip. I ended up taking it to a machine shop to get it removed.


Of course, a year later working on it I stripped out the same glow plug hole while dealing with the timing belt... so be weary of that one from now on.
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Old March 17th, 2013, 10:36 PM
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Crap half of my post didn't go though.

I was saying it would start randomly and the previous owner told us it was hard to start in the morning so I assumed maybe because it was colder outside. Then I heard they got it started but lots of black smoke at first... Seemed like un burn fuel (glow plugs or IP turned way up)

Anyways we didn't plan on taking the head off and I really didn't bring tools for that job. I had open 19mm box wrench on some of the head bolts combined with others as breaker bars. Sleeved a 10 foot pole we found on the street around my wrench to break some of those bolts.

Got the head off and pounded those glow plugs ends out with a nail and hammer. 4th one was giving us shit so we drilled it out and hammered it out in the end... All in the grass on a piece of cardboard.

I love working on this truck in the middle of nowhere with no tools. It makes you get creative with what you need to get it done. We didn't have wire for a light so we ended up mending it with an old inline fuse block we found that looked like something from the Cold War era. We also noticed we were missing some bolts on the fan pulley so we went down to meet some guy that had some parts (it was a guy in a 1 room hut with some crap on the walls) and he didn't have one, so he took us down the street to this field that was on fire and had all this metal junk laying around and we end up finding a bolt that fit. WD40 was our BP Blaster, lubricant, cleaner, air gun and hand sanitizer all in one.
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Old March 18th, 2013, 06:22 AM
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We also noticed we were missing some bolts on the fan pulley so we went down to meet some guy that had some parts (it was a guy in a 1 room hut with some crap on the walls) and he didn't have one, so he took us down the street to this field that was on fire and had all this metal junk laying around and we end up finding a bolt that fit. WD40 was our BP Blaster, lubricant, cleaner, air gun and hand sanitizer all in one.
Sounds fun. Pics!!
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