[lemondrizzle]

  Please help.

I have 2 glow plugs stuck in a Hyundai i30 1.6 crdi 2011. I have tried almost everything to get them out and I know now I have to remove the Head off the engine. Would someone be kind enough to provide me with a step-by-step guide as to how I can remove the head and what nuts require which torque settings? I am a complete novice so please feel free to treat me like a dummy and explain every little thing. Also, any additional tips that you think may help are most welcome.

Loving this forum already. 

[tw2005]

Please help.

I have 2 glow plugs stuck in a Hyundai i30 1.6 crdi 2011. I have tried almost everything to get them out and I know now I have to remove the Head off the engine. Would someone be kind enough to provide me with a step-by-step guide as to how I can remove the head and what nuts require which torque settings? I am a complete novice so please feel free to treat me like a dummy and explain every little thing. Also, any additional tips that you think may help are most welcome.

Loving this forum already.

Was the engine warm when you tried screwing these glow plugs out? I don't think a novice should ayyempt the head removal. It's also going to involve timing chain removal, and also special tools on the HP fuel pump as it's chain driven.

There are extraction kits out there but be warned most are  cheap chinese knock offs will will work but in my case the tap supplied was incorrect for the threaded extractor tool meaning it did not work. I think I did a thread on my disaster but the engine was out making it easier.

Maybe there is a workshop with experience and tooling to do it for you.

Here's an example

5205 | Laser Tools | Broken Glowplug Removal Set - YouTube

Glowplug Extraction

[nzenigma]

I have stripped and rebuilt many engines.
But, sorry mate, cannot help you.
This not the forum to provide a novice with step by step details.
It would take a page or three to write and would risk your misinterpretation.
I applaud your determination, a rare commodity in this millennial world; therefore, I suggest that you acquire a genuine workshop manual and work your way through that.

As tw2500 has advised, glow plugs should come out of a hot motor.
Go to a workshop.

[lemondrizzle]

Yes engine was cold unfortunately. I didn't think head removal would entail so much. Anyway, thank you for the warnings. 

Might have to bite the bullet and go to a garage.

[Dazzler]

  @lemondrizzle  (interesting username!)

Sorry to hear of your troubles! We had a member (moderator) @Asterix with a similar issue a couple of years ago so I have tagged him for any further comments he might like to add.

[lemondrizzle]

Thanks Dazzler.  Any advice is most welcome. I will also post and let others know of my progress, if any.

[Asterix]

As Dazz said I had to remove the head due to stuck glow plugs on my 2008 CRDi.

It turned out to be the best part of 2 working days for a trained (Hy) mechanic to remove and mount the head on these engines. Even though I'm a mechanic (Many years ago ) I chose to let the garage do the work.

After removal of the head they sent it to an engine specialist, who actually rejected to remove those 2 plugs as he couldn't ensure proper seating of the plug afterwards. I ended up with a secondhand head. It was a very expensive glow plug exchange.. 

[beerman]

@Asterix  hows the i40?

[Asterix]

@Asterix  hows the i40?

Hey @beerman   It's fantastic. I love that car. it just turned 6 y/o (105000km) and was approved at the MOT without issues. Getting around 5,1/100 in average so almost as nippy as the i30....    .... and it's a much better towcar for the caravan.. 

[lemondrizzle]

Thank you. No attempting head removal for me. May try other ideas before giving up.

[The Gonz]

I'd be tempted to consider carefully shallow drilling out the centres of the plugs and tapping them out with a left hand threaded ezi-out.

[tw2005]

I'd be tempted to consider carefully shallow drilling out the centres of the plugs and tapping them out with a left hand threaded ezi-out.

Are'nt ez -outs tapered? I think I tried that first , mine were in good but I suspect the ezout will spread the body and lock it in against the head as you twist it.

[The Gonz]

Yes, they are, mate, but if you go to the trouble of drilling, you may as well cut yourself a new straight LH thread and try pulling it out with a matching sized bolt. The ez-out was just a quick way to get the idea across.

Then the there's the very similar dentist's approach to extracting impacted wisdom teeth - drill the guts of it, shatter the remainder and draw the bits out. 

I'd be happy to do all that before getting the head off.

[nzenigma]

The pro/con with ezi-out : great when they work, but you need enough meat around the drilled hole to stop it swelling the stuck bolt.
Therefore drill smaller hole and use a smaller ezi-out;
 result:  you probably snapped that ezi-out and now have try to drill the next hole through hardened steel.

[lemondrizzle]

Hello everyone.  What do you think about taking out the injector and using a wire  hanger, bending it and pushing up the tip of the plug from there? One of the stuck plugs is just the snapped tips?

[tw2005]

Hello everyone.  What do you think about taking out the injector and using a wire  hanger, bending it and pushing up the tip of the plug from there? One of the stuck plugs is just the snapped tips?

I don't think so. If it did not unscrew with the body how stuck do you think it is.  How much angle and force will you get with a wire hanger, little I think and now add refitting and sealing the injector so new seals and and crush washers.

Just an opinion of course

@nzenigma

[lemondrizzle]

Opinions very welcome. Gives me food for thought. Thank you.

[Dazzler]

Squirt a little lemondrizzle on it and leave overnight..  Oh wait.. maybe not! 

Sorry, it's a stressful situation.. just trying to lighten the mood a bit! 

[tw2005]

Squirt a little lemondrizzle on it and leave overnight..  Oh wait.. maybe not! 

Sorry, it's a stressful situation.. just trying to lighten the mood a bit! 

A bit sour Dazz and surprised it's taken this long for that one.

[lemondrizzle]

Lol. But i have read putting coca cola in will dissolve the glow plug tip. Of course  I'll have to change the oil afterwards.  Any thoughts.......

[tw2005]

Lol. But i have read putting coca cola in will dissolve the glow plug tip. Of course  I'll have to change the oil afterwards.  Any thoughts.......

This is a joke right Got a link  to this info?

[Dazzler]

I guess you have already tried squirting penetrating oil or WD 40 or something around them and leaving 24 hours? 

[nzenigma]

Lol. But i have read putting coca cola in will dissolve the glow plug tip. Of course  I'll have to change the oil afterwards.  Any thoughts.......

This is a joke right Got a link  to this info?

    Probably a strongly held belief up there, remember, this is Little Britain led by Mother Teresa . 

  Also retaining an ancient practice that operates in a nearby back alley.   

  What do you think about taking out the injector and using a wire  hanger, bending it and pushing up ....

[rnblade]

I have read numerous threads and posts about the dreaded glow plug being seized. I decided to wimp out and let my decent garage do them. Thank god too. They called and said they’re having problems removing them and didn’t want to shear them off, but wouldn’t charge me for the extra time. Decent chaps.

[Dazzler]

I have read numerous threads and posts about the dreaded glow plug being seized. I decided to wimp out and let my decent garage do them. Thank god too. They called and said they’re having problems removing them and didn’t want to shear them off, but wouldn’t charge me for the extra time. Decent chaps.

That's impressive. Feel free to name them. Mechanics like that are hard to find. 

[tw2005]

I have read numerous threads and posts about the dreaded glow plug being seized. I decided to wimp out and let my decent garage do them. Thank god too. They called and said they’re having problems removing them and didn’t want to shear them off, but wouldn’t charge me for the extra time. Decent chaps.

removing them with a warm engine seems to be the key but so far I've removed plugs from 4 diesels and only the one I did cold turned out bad. there are extraction kits where you drill and clean out the original threads.

[nzenigma]

removing them with a warm engine seems to be the key but so far I've removed plugs from 4 diesels and only the one I did cold turned out bad. there are extraction kits where you drill and clean out the original threads.

  we have found our Einstein.   

But wait. 

Unfortunately, Real Einstein looked at the evidence, read widely, ( including NZEnigma  ) and got it right first time.  Just saying like 

[tw2005]

removing them with a warm engine seems to be the key but so far I've removed plugs from 4 diesels and only the one I did cold turned out bad. there are extraction kits where you drill and clean out the original threads.

  we have found our Einstein.   

But wait. 

Unfortunately, Real Einstein looked at the evidence, read widely, ( including NZEnigma  ) and got it right first time.  Just saying like 

It's all relative, but I think since I'm 200m from the beach right now with a blustery cool breeze, yes I'm probably am Einstein. how's that blistering hot extinct Volcano you're sitting on right now?

I don't know how you keep stuffing up these quote boxes though

[Shambles]

I don't know how you keep stuffing up these quote boxes

Help is at hand

[tw2005]

I don't know how you keep stuffing up these quote boxes

Help is at hand

Thank goodness, drives me nuts