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  #1  
Old 01-20-2020, 10:20 AM
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e53 DIESEL GLOW PLUG STUCK.

Hello,

I am very mad atm, I had a problem with my car when trying to start in the cold weather and logically I had it taken to replace the glow plugs. I took it to the local garage and had them work on replacing it, I was there watching them and when the mechanic started on screwing off the glow plugs I told him that maybe he should use some lubrication spray to loosen them up a bit, which he did but didn't wait enough time.

Anyways he managed to replace 5 glow plugs out of 6 and the last one's screwing mechanism and head got broken off and only the shaft remained in the hole. The mechanic tried to spray a lot of lubricant spray and used pliers to try to take it out but it would get out. Only the shaft of the glow plug remained I waited for like an hour for him to remove that single shaft but couldn't do it. Finally, he said it was best to just put the old screwing mechanism on top and just leave it unplugged and put everything back. I paid less money then we agreed since he couldn't fix all of them.

Now I am stuck with 5 cylinders getting all warm and cozy and one being unplugged and cold all the time. Is there a way for me to somehow remove the shaft that is stuck in the glow plug hole, the mechanic tried really hard using pliers to remove it but he said the glow plug tip might be so expanded from overuse that it's impossible to remove it and worth to leave as how it is.

Any help is appreciated thanks!

P.S. I think stuck glow plug looks something like this
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  #2  
Old 01-20-2020, 03:46 PM
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Oh no....

There is a procedure for removing glow plugs and it sounds like this mechanic didn't follow it - warm engine, penetrating oil, time etc.

There are kits to remove broken glow plugs, like this (rather expensive) one...



https://www.schmiedmann.com/en/produ...uct=9160423400

There are cheaper versions around.

You can also use some generic tools to perform an extraction, as shown in this instructable…

https://www.instructables.com/id/How...en-Glow-Plugs/

Here's your actual glow plug....



I replaced my glow plug controller and all six glow plugs about a year ago. I was VERY careful not to end up where you are, using a torque wrench to measure the undo force I was applying, so as not to break one off.
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  #3  
Old 01-20-2020, 05:02 PM
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Quote:
Originally Posted by wpoll View Post
Oh no....

There is a procedure for removing glow plugs and it sounds like this mechanic didn't follow it - warm engine, penetrating oil, time etc.

There are kits to remove broken glow plugs, like this (rather expensive) one...



https://www.schmiedmann.com/en/produ...uct=9160423400

There are cheaper versions around.

You can also use some generic tools to perform an extraction, as shown in this instructable…

https://www.instructables.com/id/How...en-Glow-Plugs/

Here's your actual glow plug....



I replaced my glow plug controller and all six glow plugs about a year ago. I was VERY careful not to end up where you are, using a torque wrench to measure the undo force I was applying, so as not to break one off.

Dear good sir wpoll,

I thank you for your deep thorough explanation, although I don’t think that incident concerns me.

For you see only my glow plug’s screwing mechanism was broken off along with its head. As for the shaft its sitting in the same place as it was before the incident. You can easily grab on it with the pliers, but its impossible to remove it from place because it seems carbon has accumulated on its tip and it is proving impossible to remove. So I need to remove the shaft safely which can be grabbed on tightly with pliers but its tip has probably thick layer of carbon which is keeping in the cylinder.

I hope I provided details more clearly, and looking forward for any tips. I also had one idea of starting the engine with the glow plug loose so maybe compression will kick it out, but I don’t know how its possible with e53 since the engine’s collector comes off in order to access the glow plugs.

Thanks in advance.
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Old 01-20-2020, 05:08 PM
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Quote:
Originally Posted by tsotnek View Post
Dear good sir wpoll,

I thank you for your deep thorough explanation, although I don’t think that incident concerns me.

For you see only my glow plug’s screwing mechanism was broken off along with its head. As for the shaft its sitting in the same place as it was before the incident. You can easily grab on it with the pliers, but its impossible to remove it from place because it seems carbon has accumulated on its tip and it is proving impossible to remove. So I need to remove the shaft safely which can be grabbed on tightly with pliers but its tip has probably thick layer of carbon which is keeping in the cylinder.

I hope I provided details more clearly, and looking forward for any tips. I also had one idea of starting the engine with the glow plug loose so maybe compression will kick it out, but I don’t know how its possible with e53 since the engine’s collector comes off in order to access the glow plugs.

Thanks in advance.
If you get the engine nice and hot, then remove the manifold in a timely fashion (10-15 mins) then you will stand a better chance of getting the broken tip out, as the carbon build-up will be softened by the heat. Once the engine gets cold, the carbon gets very hard...
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Old 01-20-2020, 06:56 PM
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And if needed M57 can be run with intake manifold removed.
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  #6  
Old 01-23-2020, 02:28 AM
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Hello,

I had created new thread because of my stupidity. It is logical I that I should post updates here so if any people will have similar problems they shall follow this steps...

anyways I had tried as recommended to remove the stuck filament when engine was really hot using pliers but it still wouldn’t budge.

here are the pictures of the broken glow plug screwing mechanism and the stuck filament.
https://imgur.com/a/nga2Dyi

Now I’ve been recommended to use - the large blind-rivet pliers! by mr. wpell.


I will have to first purchase this item. if anybody has any more recommendations they’re welcome to share.

Thanks.
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Old 01-23-2020, 04:02 AM
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I offered the suggestion of the blind rivet tool not so much to imply that this is the correct option but more to provoke other ideas that will allow some method of extrating the remaining glow plug stub.

Other possible options are the application of heat via an induction tool...



... or maybe this small bolt extractor can get a grip on the remainder of the plug and rotate/pull it out...? This is the same idea as the blind rivet tool - it has a section to grip the element...

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  #8  
Old 01-23-2020, 04:08 AM
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The smaller of this set might work...



https://www.lasertools.co.uk/product/4393
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