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REDRILL Glow Plug - Ar15.20-D-4112-01TSF

AR15.20-D-4112-01TSF  Redrill glow plug
Notes on avoiding damage through contamination and foreign objects AH00.00-P-5000-01A

Engine 651 in model 907, 910 

TORQUE SPECIFICATION HEADLESS SCREWS/BOLTS: SCREWS/BOLTS AND NUTS, COARSE-PITCH THREAD

Number Designation 8.8 10.9
BA00.10-N-1002-01A M6 Galvanized Nm 9 13
Phosphated Nm 9 12
TORQUE SPECIFICATION HEADLESS SCREWS/BOLTS: SCREWS/BOLTS AND NUTS, COARSE-PITCH THREAD

Number Designation 12.9
BA00.10-N-1002-01A M6 Galvanized Nm 16
Phosphated Nm 14
Fig 1: Glow Plug Repair Kit, M8 (651 589 00 99 00)
G13789820
Fig 2: Glow Plug Repair Set (642 589 01 99 00)
G13789821
Fig 3: Glow Plug Repair Kit, M8 (642 589 00 99 00)
G13789822
Fig 4: Record Plug (611 589 00 91 00)
G13789823
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 kit, M8 642 589 00 99 00 

G13789824

Shown: Glow plug repair kit, M8 651 589 00 99 00 

G13789825

Shown: Glow plug repair kit, 642 589 01 99 00 

G13789826

IMPORTANT Use following special tools: SPECIAL TOOL Glow plug repair kit, M8 642 589 00 99 00 and SPECIAL TOOL glow plug repair kit, M8 651 589 00 99 00.

For a glow plug thread M10x1 additionally use: SPECIAL TOOL Glow plug repair set 642 589 01 99 00.

IMPORTANT Screw (4a) of bracket (4) from SPECIAL TOOL glow plug repair kit, M8 642 589 00 99 00 is used to mount bayonet guide (7) on mounting rail (20).

Prepare the glow plug 

  1. Position stud extractor (1) for diam. 4 mm on pin of glow plug cap and tear off center electrode of glow plug by turning to right.

    IMPORTANT Remove all loose parts.

    NOTES After each material removing operation step, immediately remove chips (e.g. by suctioning or brushing off and collecting) or clean bores with round wire brushes (18, 19).

    Damage may occur on the engine otherwise.

    G13789827
    G13789828
  2. Tear off center electrode of glow plug with stud extractor (1) for diam. 2.5 mm again.

    If center electrode of glow plug is not broken or torn off at lower end but directly behind cap of electrical connection.

    If tearing off center electrode of glow plug again is not possible,

    IMPORTANT This stabilizes the center electrode when drilling out.

    IMPORTANT For glow plug thread M8x1, use drill-out sleeve (2) with inside diameter of 2.6 mm.

    For glow plug thread M10x1, use drill-out sleeve (2) with inside diameter of 3 mm.

    If drill-out sleeve (2) cannot be tapped in flush, cut off protruding part of drill-out sleeve (2) flush with side cutting pliers.

    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.

    Attach and align the boring out jig 

  3. Loosely attach mounting rail (20) with mounting angle (21) and screws (22, 23) on cylinder head.

    IMPORTANT Use screw/bolts (23) for rail.

  4. Press mounting rail (20) downwards (arrows) and tighten screws (23) TORQUE SPECIFICATION .
    G13789829
  5. Guide centering and support tube (6) with thinner end from beneath into bayonet guide (7).

    When drilling out glow plug on cylinders 1, 2 or 3.

    G13789830
  6. Align centering and support tube (6) with bayonet guide (7) over glow plug to be drilled out on mounting rail (20) and tighten screw (4a) TORQUE SPECIFICATION .

    When drilling out glow plug on cylinders 1, 2 or 3.

  7. Push the centering and support pipe (6) into the glow plug well (arrow) and center it.

    When drilling out glow plug on cylinders 1, 2 or 3.

    IMPORTANT Through turning the combined drilling and extraction device (20) center the centering and support pipe (6) in such a way that it is aligned with the glow plug.

    G13789831

    Shown on cylinder 1 

  8. Tighten screws (22) of mounting rail (20) TORQUE SPECIFICATION .

    When drilling out glow plugs on cylinders 1, 2 or 3.

    IMPORTANT After tightening the screw/bolts (22) 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 this does not apply, repeat centering process.

    G13789832

    Shown on engine 651 in model 907 

  9. Remove bayonet guide (7) from mounting rail (20) and remove centering and support tube (6).

    When drilling out glow plug on cylinders 1, 2 or 3.

  10. Attach bayonet guide (7) to mounting rail (20) and tighten screw (4a) TORQUE SPECIFICATION .

    Shown on cylinder 1 

    G13789833
  11. Introduce the combination bracket (24) through the bayonet guide (7) into the glow plug well.

    When drilling out glow plug on cylinder 4.

    IMPORTANT "IN/OUT POSITION" lettering on combination bracket (24) must point upwards.

  12. Center the combination bracket (24) in the glow plug well (arrow).

    When drilling out glow plug on cylinder 4.

    G13789834

    IMPORTANT By moving mounting rail (20), center combination bracket (24) in bayonet guide (7) so that it aligns with glow plug.

    Shown on cylinder 4 

  13. Tighten down both screw/bolts (22) for the mounting rail (20) TORQUE SPECIFICATION .

    When drilling out glow plug on cylinder 4.

    IMPORTANT After tightening the screw/bolts (22) it must still be possible to introduce the combination bracket (24) into the glow plug well and to pull it out again without special use of force.

  14. Pull combination bracket (24) out from bayonet guide (7).

    When drilling out glow plug on cylinder 4.

    If this does not apply, repeat centering process.

    G13789835

    Shown on cylinder 1 

    Redrill glow plug 

  15. Clamp stepped drill bit (8) into combination bracket (24) and oil stepped drill bit (8) as well as combination bracket (24).

    If drill-out sleeve (2) was tapped in beforehand.

    IMPORTANT For glow plug thread M8x1, use stepped drill bit (8) with inscription "M8".

    For glow plug thread M10x1, use stepped drill bit (8) with inscription "M10".

  16. Insert combination bracket (24) with stepped drill bit (8) into bayonet guide (7).

    If drill-out sleeve (2) was tapped in beforehand.

    IMPORTANT On cylinder 4, "IN/OUT POSITION" lettering of combination bracket (24) must point upwards.

  17. Drill glow plug 2 to 3 mm deep in center.

    If drill-out sleeve (2) was tapped in beforehand.

  18. Pull combination bracket (24) out from bayonet guide (7) and remove stepped drill bit (8).

    If drill-out sleeve (2) was tapped in beforehand.

  19. Clamp special drill bit (17) into combination bracket (24) and oil special drill bit (17) as well as combination bracket (24).

    If drill-out sleeve (2) was tapped in beforehand.

    IMPORTANT For glow plug thread M8x1, use special drill bit (17) with diam. 4.5 mm.

    For glow plug thread M10x1, use special drill bit (17) with diam. 5.5 mm.

  20. Drill out the center electrode of the glow plug until the combination bracket (24) almost touches the cylinder head.

    If drill-out sleeve (2) was tapped in beforehand.

  21. Pull combination bracket (24) out from glow plug and bayonet guide (7) and remove special drill bit (17).

    If drill-out sleeve (2) was tapped in beforehand.

  22. Clamp stepped drill bit (8) into combination bracket (24) and oil Lubricate.

    IMPORTANT For glow plug thread M8x1, use stepped drill bit (8) with inscription "M8".

    For glow plug thread M10x1, use stepped drill bit (8) with inscription "M10".

    Shown on cylinder 1 

    G13789836
  23. Insert combination bracket (24) with stepped drill bit (8) through bayonet guide (7).

    IMPORTANT On cylinder 4, "IN/OUT POSITION" lettering of combination bracket (24) must point upwards.

  24. Drill out core of glow plug thread to marking "1st STOP OM651".

    IMPORTANT Drill out core of glow plug thread by repositioning stepped drill bit (8) several times. Drill out core of glow plug thread until marking "1st STOP OM651" on combination bracket (24) reaches upper edge of bayonet guide (7).

  25. Pull out combination bracket (24) with stepped drill bit (8) from bayonet guide (7).
  26. Clean working area and bore.
  27. Clamp thread tap (10) into combination bracket (25) and oil thread tap (10) as well as combination bracket (25).

    IMPORTANT For glow plug thread M8x1, use thread tap (10) with inscription "UNF no. 12". For glow plug thread M10x1, use thread tap (10) with inscription "UNF 1/4".

    Shown on cylinder 1 

    G13789837
  28. Insert combination bracket (25) with thread tap (10) into bayonet guide (7).

    IMPORTANT On cylinder 4, "IN/OUT POSITION" lettering of combination bracket (25) must point upwards.

  29. Attach tool holder (16) on combination bracket (25) and cut a thread in 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.

  30. Remove thread tap (10) and pull combination bracket (25) out from bayonet guide (7).
  31. Clean working area and thread.
  32. Oil combination bracket (24) and stepped drill bit (8).
  33. Insert combination bracket (24) with stepped drill bit (8) through bayonet guide (7).

    IMPORTANT For glow plug thread M8x1, use stepped drill bit (8) with inscription "M8". For glow plug thread M10x1, use stepped drill bit (8) with inscription "M10".

    IMPORTANT On cylinder 4, "IN/OUT POSITION" lettering of combination bracket (24) must point upwards.

    Shown on cylinder 1 

    G13789838
  34. Bore out the remaining glow plug thread.

    IMPORTANT By repositioning stepped drill bit (8) several times, drill out remaining glow plug thread until combination bracket (24) almost rests on cylinder head.

  35. Pull out combination bracket (24) with stepped drill bit (8) from bayonet guide (7).
  36. Remove stepped drill bit (8) from combination bracket (24).
  37. Clean working area and bore.
  38. Insert combination bracket (25) with thread tap (10) into bayonet guide (7).

    IMPORTANT On cylinder 4, "IN/OUT POSITION" lettering of combination bracket (25) must point upwards.

  39. 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.

    Shown on cylinder 1 

    G13789839
  40. Remove thread tap (10) and pull combination bracket (25) out from bayonet guide (7).
  41. Remove stepped drill bit (10) from combination bracket (25).
  42. Clean working area, bore, and thread.
  43. Remove screw (4a) and remove bayonet guide (7) from mounting rail (20).

    Shown on cylinder 1 

    G13789840
  44. Introduce the centering and support pipe (6) with the thicker end into the glow plug well.
  45. Screw extraction spindle (12) into previously cut thread and tighten.

    IMPORTANT For glow plug thread M8x1, use an extraction spindle (12) with thread "UNF no. 12".

    For glow plug thread M10x1, use an extraction spindle (12) with thread "UNF 1/4".

  46. Grease extraction spindle (12).

    Shown on cylinder 4 

    G13789841
  47. Screw bearing unit (13) onto extraction spindle (12).

    Shown on cylinder 1 

    G13789842
  48. Counterhold extraction spindle (12) and pull out remains of glow plug (14) by turning bearing unit (13).

    NOTES Always counterhold extraction spindle (12) when turning bearing unit (13). Damage may occur otherwise on the cylinder head.

    If extraction process offers excessive resistance,

    ↓

    Loosen the bearing unit (13) again and carefully tap the end of the extraction spindle (12) with a hammer.

    G13789843
    G13789844

    Shown on cylinder 4 

  49. Clean glow plug hole with round wire brush (18, 19).

    IMPORTANT For glow plug thread M8x1, use round wire brush (18) with diam. 7 mm and round wire brush (19) with diam. 4.2 mm.

    For glow plug thread M10x1, use round wire brush (18) with diam. 8.5 mm and round wire brush (19) with diam. 5.3 mm.

    G13789845

    Recut the glow plug thread in the cylinder head 

  50. Insert a grommet from the SPECIAL TOOL set of stop plug in the glow plug hole.
  51. Attach bayonet guide (7) with screw (4a) on mounting rail (20) over glow plug hole TORQUE SPECIFICATION .
    G13789846
  52. Clamp thread tap (15) into combination bracket (25) and fill flutes of thread tap (15) with grease.

    IMPORTANT For glow plug thread M8x1, use thread tap (15) with inscription "M8x1".

    For glow plug thread M10x1, use thread tap (15) with inscription "M10x1".

  53. Insert combination bracket (25) into bayonet guide (7).

    IMPORTANT On cylinder 4, "IN/OUT POSITION" lettering of combination bracket (25) must point upwards.

    G13789847

    Shown on cylinder 1 

  54. Attach tool holder (16) on combination bracket (25) and recut glow plug thread in cylinder head to clean.
  55. Remove the combination bracket (25) from the bayonet guide (7).
  56. Clean glow plug thread in cylinder head and glow plug hole.
  57. Check glow plug thread in cylinder head for damage.

    If the glow plug thread is damaged,

    Repair the glow plug thread using the thread repair set.

  58. Remove stop plug from SPECIAL TOOL stop plug set from glow plug hole.

    Remove the boring out jig 

  59. Remove bayonet guide (7).
  60. Remove screws (23) and remove mounting rail (20) with mounting angles (21) from cylinder head.
G13789848
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