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

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

Engine 642 in model 907 

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
TORQUE SPECIFICATION CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER

Number Designation Engine 642 in model 907
BA01.20-N-1001-01O Screw/bolt, cylinder head cover to cylinder head Stage 1, apply Nm 4
Stage 2, initial torque Nm 6
Stage 3, final torque Nm 8
Fig 1: Glow Plug Repair Kit, M8 (642 589 00 99 00)
G13789849
Fig 2: Record Plug (611 589 00 91 00)
G13789850
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
G13789851

IMPORTANT Use the following special tool: SPECIAL TOOL Glow plug repair kit, M8 642 589 00 99 00.

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.

  1. Place stud extractor (1) for a diameter of 4 mm on the pin of the cap of the glow plug and remove center electrode of the glow plug by turning it clockwise.

    IMPORTANT Remove all loose parts.

    G13789852
    G13789853
  2. Tear off center electrode of glow plug with stud extractor (1) for diam. 2.5 mm again.

    If the center electrode of the glow plug is broken not on the bottom end but rather immediately behind the cap of the electrical connection.

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

    ↓

    Hammer in the drill-out sleeve (2) using a hammer and punch flush into the glow plug.

    If drill-out sleeve (2) cannot be tapped in flush,

    ↓

    cut off protruding part of drill-out sleeve (2) flush with side cutting pliers.

    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.

    IMPORTANT This stabilizes the center electrode when drilling out.

    IMPORTANT Use a drill-out sleeve (2) with an inside diameter 2.6 mm.

    Attach and align the boring out jig 

  3. Remove screw/bolts (3) of the cylinder head cover in the area of the broken off glow plug.
  4. Attach combined drilling and pull-off device (4) with fit screws (5) to the cylinder head cover.

    IMPORTANT Screw in fit screws (5) slightly by hand.

    G13789854
    G13789855
  5. Lead the centering and support pipe (6) with the smaller diameter from below into the bayonet guide (7).
  6. Attach bayonet guide (7) with centering and supporting tube (6) to the combined drilling and pull-off device (4) and tighten screw (4a) TORQUE SPECIFICATION .
    G13789856
    G13789857
  7. Push the centering and support pipe (6) into the glow plug well and center it.

    IMPORTANT Through turning the combined drilling and extraction device (4) center the centering and support pipe (6) in such a way that it is aligned with the glow plug.

  8. Tighten fit screws (5) TORQUE SPECIFICATION .
    G13789858
    G13789859

    IMPORTANT After tightening the fit bolts (5) 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 not, repeat the centering process.

  9. Remove the bayonet guide (7) from the combined drilling and extracting tool (4) and remove the centering and supporting tube (6).
  10. Attach the bayonet guide (7) to the combined drilling and extracting tool (4).
    G13789860

    Redrill glow plug 

  11. Clamp stepped drill bit M8 (8) into the drill holder (9) and lubricate stepped drill bit M8 (8) and drill holder (9)
  12. Insert drill holder (9) with stepped drill bit M8 (8) into bayonet guide (7).

    If a drill-out sleeve (2) was previously stamped in.

  13. Drill glow plug 2 to 3 mm deep while centered.

    If a drill-out sleeve (2) was previously stamped in.

  14. Pull drill holder (9) out of the bayonet guide (7) and remove stepped drill bit M8 (8).

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

  15. Clamp special drill (17) with a diameter of 4.5 mm into the drill holder (9) and lubricate special drill (17) with a diameter of 4.5 mm and the drill holder (9).

    If a drill-out sleeve (2) was previously stamped in.

  16. Drill out the center electrode of the glow plug until the drill holder (9) almost touches the cylinder head.

    If a drill-out sleeve (2) was previously stamped in.

  17. Pull drill holder (9) out of the glow plug and bayonet guide (7) and remove special drill (17).

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

  18. Clamp stepped drill bit M8 (8) into the drill holder (9) and lubricate stepped drill bit M8 (8) and drill holder (9)
  19. Insert drill holder (9) with stepped drill bit M8 (8) into bayonet guide (7).
  20. Drill out core of the glow plug thread up to marking (A).
    G13789861
    G13789862

    IMPORTANT Through multiple putting down of the graduated drill M8 (8) bore out the glow plug thread at the core until the marking (A) on the drill holder (9) reaches the upper edge of the bayonet guide (7).

  21. Pull drill holder (9) with stepped drill bit M8 (8) out of the bayonet guide (7).
  22. Clean working area and bore.
  23. Clamp thread tap "UNF no. 12" (10) into the thread tap holder (11) and lubricate thread tap "UNF no. 12" (10) and thread tap holder (11)
    G13789863
  24. Insert thread tap holder (11) with thread tap "UNF no. 12" (10) into bayonet guide (7).
  25. Attach tool holder with ratchet wrench (16) to thread tap holder (11) and cut a thread in the glow plug body.

    IMPORTANT Cut the thread as a right-hand thread as deep as possible into the glow plug body. Lubricate thread tap "UNF no. 12" (10) multiple times when doing so.

  26. Remove thread tap "UNF no. 12" (10) and pull with the thread tap holder (11) out of the bayonet guide (7).
  27. Clean working area and bore.
    G13789864
  28. Lubricate stepped drill bit M8 (8) and drill holder (9)
  29. Insert drill holder (9) with stepped drill bit M8 (8) through the bayonet guide (7).
  30. Bore out the remaining glow plug thread.

    IMPORTANT By putting down the stepped drill bit multiple times M8 (8), drill out the glow plug thread until the drill holder (9) almost stands on the cylinder head.

  31. Pull drill holder (9) with stepped drill bit M8 (8) out of the bayonet guide (7).
  32. Clean working area and bore.
    G13789865
  33. Lubricate thread tap "UNF no. 12" (10) and thread tap holder (11)
    G13789866
  34. Insert thread tap holder (11) with thread tap "UNF no. 12" (10) into bayonet guide (7).
  35. 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 thread tap "UNF no. 12" (10) multiple times when doing so.

  36. Remove thread tap "UNF no. 12" (10) and pull with the thread tap holder (11) out of the bayonet guide (7).
    G13789867
  37. Clean working area and bore.
  38. Screw extraction spindle (12) through the bayonet guide (7) into the previously cut thread and tighten.
  39. Lead the centering and support pipe (6) with the thinner diameter from below into the bayonet guide (7) and glow plug well.
  40. Grease extraction spindle (12).
    G13789868
  41. Screw bearing unit (13) onto extraction spindle (12).
  42. Counterhold extraction spindle (12) and remove remains of the glow plug by turning the 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.

    G13789869
  43. Clean glow plug hole with round wire brush (18, 19).
    G13789870

    Recut the glow plug thread in the cylinder head 

  44. Insert a grommet from the SPECIAL TOOL set of stop plug in the glow plug hole.
  45. Clamp thread tap M8x1 (15) into the thread tap holder (11) and fill flutes of the thread tap M8x1 (15) with grease.
  46. Insert thread tap holder (11) with thread tap M8x1 (15) into the bayonet guide (7).
  47. Recut the fastening thread of the glow plug in the cylinder head clean.
  48. Remove thread tap holder (11) with thread tap M8x1 (15) from the bayonet guide (7).
  49. Clean fastening thread of the glow plug in the cylinder head and the glow plug hole.
  50. Check fastening thread of the glow plug in the cylinder head for damage.

    If the fastening thread of the glow plug is damaged,

    ↓

    repair the fastening thread of the glow plug with the thread repair set.

  51. Remove stop plug from SPECIAL TOOL stop plug set from glow plug hole.
    G13789871

    Remove the boring out jig 

  52. Remove bayonet guide (7) from combined drilling and pull-off device (4).
  53. Remove fit screws (5) and remove combined drilling and pull-off device (4).
    G13789872
    G13789873
  54. Screw in screw/bolt (3) TORQUE SPECIFICATION .
G13789874
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