Glow Plug Removal gone wrong...

**djl78** · 17-01-2009,12:47 PM

Whilst changing glow plugs this morning i think i may have sheared one off or damaged the thread.It continues to turn fairly loosely but will neither undo or tighten.
This is looking frighteningly like a cylinder head off job.
Any ideas or advice would be greatly appreciated.

Allroad 2.5 TDI engine code AKE.

Thanks
d

**Peter D** · 17-01-2009,01:10 PM

Are you sure you have not sheared the flats off the glowplug. what size and seach of socket did you use. Regards Peter

**djl78** · 17-01-2009,01:13 PM

Hi Peter,
I used a 10mm deep socket.The flats look fine so i'm thinking it may be the thread.
Thanks

**Peter D** · 17-01-2009,01:16 PM

Do not start the car until you know what has happened. The plug could be ejected at considerable speed. Regards Peter

**djl78** · 17-01-2009,01:23 PM

Thanks for info.I wasn't going to start the car just in case a section of plug has broken off.
There is a opening in the side of the cylinder casting so i'll see if i can get something in to lever whilst unscrewing.
Thanks again peter

**Peter D** · 17-01-2009,01:24 PM

Does the top of plug rotate. There is a small undercut on the top the the treaded section and it may have sheared. Regards Peter

**djl78** · 17-01-2009,01:32 PM

I've just had another look and that appears to be the problem.The centre of the plug is not rotating but the flats are so i think you're right.
Options now i guess are cylinder head off,remove plug and insert a helicoil provided there is no more damage.
Is there anything i should be aware of whilst removing head?I have some manuals which are quite detailed.

Thanks
d

**Peter D** · 17-01-2009,01:41 PM

Ring a deisel specialist or an Audi Independant and explain to them. They made have some ideas. First thing to do is use a wrap of insulation tape over lapping the end of the socket, ease it over the fractured part and list up the hex part and remove. Do this before you apply Plus Gas to soak the threads. You may be lucky and the thread may just let go. Speak to a specialist or indi now as they may be closing as it is Saturday. Regards Peter