OM605 Broken GP

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Tony From West Oz
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OM605 Broken GP

Post by Tony From West Oz » Thu 20 Jul, 2017 1:19 am

I have had one GP break off when trying to remove it. $500 later and it has been removed and replaced.
I now have another GP dead and I am reluctant to try to remove it. Does anyone have recommendations on how to get it out without breaking the GP off?
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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John Green
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Re: OM605 Broken GP

Post by John Green » Thu 20 Jul, 2017 11:40 am

Try to tighten it before you try to untighten it..
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Tony From West Oz
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Re: OM605 Broken GP

Post by Tony From West Oz » Thu 20 Jul, 2017 5:40 pm

Thanks John, I will give it a go.
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

tsharkey
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Re: OM605 Broken GP

Post by tsharkey » Thu 20 Jul, 2017 10:05 pm

What John says make sense - The other theories I have heard about trying to soak it first doesn't gell with me as they seize on the other side of the thread.

I bought the removal jig from Spain which drills, then uses a tap to pull the remainder out. It is beautifully engineered, is specific to OM605/6, works well but you have to have nerves of steel as you are drilling into your head ! Fortunately I use a lot of Spanish in my work because the instructions were not in english.
W123 1981 300TD - Family Kid mover
W202 1998 C250D Factory OM605A Turbo - Partner's daily driver
W123 1982 300CD Retro fitted OM617A Turbo - Mine
W123 1984 300TD 5 Speed Manual, to teach the kids how to drive
W123 1982 300TD Factory OM617A Turbo (Hans) - Project
W123 1985 230TE - Brother's
W123 1985 300D - Sister in Law's
1962 S-Series Valiant (Tho Daimler & Chrysler divorced, still part of the extended family)

Past benzes
W114 1969 250CE - PO put in an M110 transplant and nearly sent me around the bend
W123 1981 300TD - "Matilda" - RIP hit front side & rear but left my brother + niece A-OK

Current Projects
Coupe restoration, Turbo Wagon freshen up

ChristoC
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Re: OM605 Broken GP

Post by ChristoC » Thu 20 Jul, 2017 10:33 pm

So, whilst you are drilling, it helps to repeat "pajero" does it?


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merc-304
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Re: OM605 Broken GP

Post by merc-304 » Fri 21 Jul, 2017 9:40 am

Diesel pump uk has a vid on Utube of seized Glow plug removal.
380 SEC

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SantoC
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Re: OM605 Broken GP

Post by SantoC » Sun 06 Aug, 2017 11:53 pm

Tony From West Oz wrote:Does anyone have recommendations on how to get it out without breaking the GP off?
Here is what I do. Most of the information are from various forums and websites I've gathered/collected over the years.
1. Keep warm engine, due to the difference in expanding alloy engine vs GP steel. Hard to measure its efficacy, but i do it anyhow.
2. focus on one GP at a time.
3. As John states, initially tighten GP to break the carbon seal.
4. As you're progressively untighten GP, tighten it every so often.
5. use penetrating oil
6. Make patience your best friend
7. Recently I've been using a torque wrench (I set it at max 45Nm). The rationale here is some guy overseas tested breaking/snapping points of GP's. I can't remember his results but I think they snap around 60+Nm. I find using a torque wrench really useful. It allow me to gauge force. If it requires more force than desired Nm setting, refer to no. 4 & 5 & 6.

Towards the end, once it's out of the tread, it can be quite hard to pull the GP out. You can use pliers. I find a rattle gun useful here. It breaks off any carbon surrounding the GP.

Don't forget to ream out the carbon. You will be amazed how much comes out!

Test new GP with jumper leads to ensure it works before installation.

Use anti-seize compound on GP thread and body. Then install.

Good luck!

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Tony From West Oz
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Re: OM605 Broken GP

Post by Tony From West Oz » Mon 07 Aug, 2017 2:43 am

Thanks a lot everyone. I will get onto the GP this week as I now have another vehicle (Musso) I can use in the rain (My 300CD has windscreen leak causing water ingress when in the rain), so the urgency of getting it out and the replacement back in is not an issue. I can take my time with it. I like the idea of using a torque wrench. I have one I can use, which operates in both directions, I just need to switch the ratchet toggle for the direction of turning.

I also have a copper based anti seize grease I could apply to the thread of the GP. Any thoughts about its use in this application?
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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SantoC
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Re: OM605 Broken GP

Post by SantoC » Fri 18 Aug, 2017 9:36 am

Tony From West Oz wrote:I have had one GP break off when trying to remove it. $500 later and it has been removed and replaced.
Tony, I'm curious to know the procedure undertaken to remove the broken GP?

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Tony From West Oz
OZBENZ moderator
Posts: 3133
Joined: Mon 20 Jun, 2005 10:04 pm
Model you own: w202
Location: Bedfordale WA

Re: OM605 Broken GP

Post by Tony From West Oz » Fri 18 Aug, 2017 11:19 pm

Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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