Drilling the glow plug

a
AR15.20-B-4112-01A.fm

Drilling the glow plug

AR15.20-B-4112-01A.fm

Engine 611, 612

n Pre-heating system
Number

Designation

BA15.20-B-1001-01A

Glow plug to cylinder head

BA15.20-B-1002-01A

602 589 00 33 00
Impact puller

Engine 611.981/
983

Engine 612.983

Nm

19

19

Threaded insert, for glow plug, to cylin- Nm

der head

20

20

611 589 00 91 00
Plug for glow plug housing in cyl-

611 589 00 99 00
Repair kit

inder head
Repair products
Number

Designation

BR00.45-B-1014-01A

Chemical lock - Loctite 262

Order number

Drilling the glow plug

AR15.20-B-4112-01A.fm

p At every work step that generates chips, the drilling must be cleaned with compressed air
jets or vacuum cleaner and the guide bushings with the round brush supplied with the repair kit.
a Use safety goggles.
1
Insert the 8 mm diameter guide bushing (2) until touching the cylinder head.
2
Attach the depth limiter (4) to the 8 mm diameter drill bit (3), at distance (A).
3
Drill the glow plug with 8 mm diameter, until the depth limiter (4), on the drill bit (3) touches the
guide bushing (2).
i Drill slowly, pull drill several times out of the hole to remove the chips.
4
Remove the guide bushing (2) from cylinder head.
p Remove chips with compressed air jets or vacuum cleaner.
A = 85 mm

5
6
7
8

B15.20-0006-01

Insert the 8 mm diameter guide bushing (2) until touching the cylinder head and the 6 mm diameter guide bushing (9) until touching the guide bushing (2).
Attach the depth limiter (11) to the M6 tap (10), at distance (C).
Tap the M6 thread inside the glow plug, until the depth limiter (11) on tap (10) touches the guide
bushing (9). Use the extension (12).
Remove the 6 mm diameter guide bushing (9) from the 8 mm diameter guide bushing (2).

p Remove chips with compressed air jets or vacuum cleaner.

C = 120 mm

B15.20-0005-02

Drilling the glow plug

a
9
10

AR15.20-B-4112-01A.fm

Thread the M6 adapter (13) to the glow plug.

Thread the impact puller l to the M6 adapter (13) and remove the glow plug from cylinder
head.

i If the complete glow plug has been removed, go to job step 23.
i If the glow plug has not been completely removed, carry out job steps starting at step 11.

B15.20-0007-01
11
12
13
14

Insert the 8 mm diameter guide bushing (2) until touching the cylinder head and the 3.5 mm diameter guide bushing (14) until touching the guide bushing (2).
Attach the depth limiter (16) to the 3.5 mm diameter drill bit (15), at distance (D).
Drill the glow plug with 3.5 mm diameter, until the depth limiter (16) on drill bit (15) touches the
guide bushing (14).
Remove the 3.5 mm diameter guide bushing (14) and the 8 mm diameter (2) from cylinder head.

p Remove chips with compressed air jets or vacuum cleaner.

D = 150 mm

B15.20-0008-01

Drilling the glow plug

a
15
16
17
18

AR15.20-B-4112-01A.fm

Insert the 4.2 mm diameter guide bushing (17) until touching the cylinder head.
Attach the depth limiter (19) to the M4 tap (18), at distance (E).
Tap M4 thread inside the glow plug, until the depth limiter (19) on tap (18) touches the guide
bushing (17). Use the extension (20).
Remove the 4.2 mm diameter guide bushing (17) from the cylinder head.

p Remove chips with compressed air jets or vacuum cleaner.

E = 110 mm

B15.20-0009-01
19
20
21

Insert the 8 mm diameter guide bushing (2) until touching the cylinder head.
Screw the M4 adapter (21) into glow plug.
Screw the impact puller l to the M4 adapter (21) and remove glow plug from the cylinder head.

B15.20-0010-01

Drilling the glow plug

a
22
23
24

AR15.20-B-4112-01A.fm

Remove the 8 mm diameter guide bushing (2) from the cylinder head.
Screw plug l (35) on M6 adapter (13) and plug the glow plug mounting hole in cylinder head.
Using a M10 tap (22), chase the M10 thread for installing the glow plug in cylinder head.

p Remove chips with compressed air jets or vacuum cleaner.

25
26

Remove the plug l (35) from the glow plug mounting hole in cylinder head, using the M6
adapter (13).
Install the glow plug in cylinder head with the specified tightening torque n.

i If the glow plug is tight, suppress the next job steps.

i If the glow plug is not tight, carry out job steps starting at 27.

27

Screw plug l (35) on M6 adapter (13) and plug the glow plug mounting hole in cylinder head.

B15.20-0012-02

Drilling the glow plug

a
28
29

AR15.20-B-4112-01A.fm

Widen the tapped hole in cylinder head using the 11 mm diameter

reamer (23).
Tap M12 thread in cylinder head using the M12 tap (24).

p Remove chips with compressed air jets or vacuum cleaner.

30

Remove the plug l from the glow plug mounting hole in cylinder
head with the M6 adapter.

B15.20-0013-11
31
32
33
34
35
36

Clean the thread in cylinder head and the external M12 thread on insert (25), eliminating oil or
grease.
Lightly oil the thread on installation tool (26) and the internal M10 thread of insert (25).
Screw the insert (25) onto installation tool (26).
Apply chemical lock (Loctite 262) to external M12 thread of insert (25).
Screw the insert (25) into the cylinder head tightening it to the specified torque n.
Unscrew the installation tool (26) from insert (25).

B15.20-0014-01

Drilling the glow plug

AR15.20-B-4112-01A.fm