Anyone ever broken a Glow plug??

[topless96]

I was just putting a low mileage motor back into my 2000 tdi and said why not replace all the glow plugs while it is out on the stand. Mistake. Now 3 out of 4 glow plugs came out easy but one snapped and just turns. I broke off the head of the plug so I could drill the plug for an easy out. But no luck still stuck. Can I heat up the plug and head a little so maybe th PB Blaster can work better? Any tricks in the TDI bag?

[CoolAirVw]

Try the heat, yes. 

If any peices end up in the cylinder do not start it! 

You may end up needing to pull the head.

[the caveman]

That's kind of a problem with TDI's .The glow plugs last so long that when it comes time to change one it can be a disaster. I had one guy in this week with a 98 and he's was pretty sure none were changed for at least 6 years

[745 turbogreasel]

so..
1) the threads  unscrewed, then the swollen tip broke?
or
2)the hex broke off the thread portion?


1) combustion pressure will sometimes remove it

2) Weld a nut to the remains and unscrew?

[topless96]

Got it out!!!  Heat and jammed a torks bit into the drilled hole and closed my eyes. Heated with a very thin flame then let it cool. When I felt it give I was so happy for not having to pull the head. Got lucky this time!

[745 turbogreasel]

[trev0006]

I think welding is removing is your best bet.

I was just putting a low mileage motor back into my 2000 tdi and said why not replace all the glow plugs while it is out on the stand. Mistake. Now 3 out of 4 glow plugs came out easy but one snapped and just turns. I broke off the head of the plug so I tires cars could drill the plug for an easy out. But no luck still stuck. Can I heat up the plug and head a little so maybe th PB Blaster can work better? Any tricks in the TDI bag?