Broken Glow Plug Tip and Electrode Removal Kit, M8 and M10

This tool kit is designed for removing broken glow plug tips and electrodes that remain inside the cylinder head after the glow plug body has been removed.

It is suitable for glow plugs with the following thread sizes:

• M8×1.0
• M10×1.0
• M10×1.25

Guided Drilling and Thread Preparation

The appropriate guide bolt is installed in the glow plug thread to guide and centre the twist drill accurately over the broken tip.

After drilling, the corresponding tap is used to cut an extraction thread into the remaining glow plug component. The pulling spindle and spindle guide then allow the broken tip to be extracted in a controlled manner.

Scope of Delivery

• 1 × pulling spindle, M3×0.5×100 mm
• 1 × twist drill, 3.3×140 mm
• 1 × twist drill, 2.5×120 mm
• 1 × tap, M4×0.7
• 1 × tap, M3×0.5
• 1 × pulling-spindle guide, M10×1.25
• 1 × pulling-spindle guide, M10×1.0
• 1 × pulling-spindle guide, M8×1.0
• 1 × guide bolt, M10×1.25, internal diameter 3.5 mm
• 1 × guide bolt, M10×1.0, internal diameter 3.5 mm
• 1 × guide bolt, M8×1.0, internal diameter 3.5 mm
• 2 × guide bolts, M8×1.0, internal diameter 2.5 mm
• 1 × guide bolt, M10×1.0, internal diameter 4.5 mm
• 1 × guide bolt, M10×1.25, internal diameter 4.5 mm
• 1 × additional guide bolt, M10×1.0, internal diameter 3.5 mm
• 1 × additional guide bolt, M10×1.25, internal diameter 3.5 mm
• 2 × spindle nuts, M4×0.7
• 1 × spindle nut, M3×0.5

Removing a Broken Glow Plug Tip from the Cylinder Head

1. The glow plug body, including the hexagonal drive and electrical connection, can be removed normally. If the glow plug tip breaks off and remains inside the cylinder head, it can only be removed using a suitable extraction tool or after removing the cylinder head.
2. Select and install the appropriate guide bolt for drilling out the broken glow plug tip. The guide bolt must be selected according to its length, internal diameter, and the diameter of the thread or drill being used.
3. Using the appropriate twist drill, carefully drill into the broken glow plug tip. Select the drill diameter according to the size of the glow plug tip:
   • 2.5 × 120 mm twist drill
   • 3.3 × 140 mm twist drill
4. Remove the guide bolt and cut a thread into the drilled glow plug tip using the appropriate tap. The tap size depends on the drill previously used:
   • M3 × 0.5 tap when using the 2.5 × 120 mm drill
   • M4 × 0.7 tap when using the 3.3 × 140 mm drill
5. Screw the appropriate extraction spindle into the newly cut thread in the glow plug tip:
   • M3 × 0.5 × 100 mm extraction spindle
   • M4 × 0.7 × 100 mm extraction spindle
6. Install the appropriate extraction spindle guide.
7. Fit the spindle nut onto the extraction spindle.
8. Using a suitable tool, turn the spindle nut against the extraction spindle guide. This gradually pulls the broken glow plug tip upwards and out of the cylinder head.
9. Once completely extracted, remove the broken glow plug tip from the extraction spindle.