CLAS OM 3778 Extraction Box for Damaged Glow Plugs Instruction Manual

: June 13, 2024
: CLAS

Table of Contents

CLAS OM 3778 Extraction Box for Damaged Glow Plugs
Product Information
Product Usage Instructions
GLOW PLUG REMOVAL SET
BEFORE STARTING
INSTRUCTIONS
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Download This Manual (PDF format)

CLAS OM 3778 Extraction Box for Damaged Glow Plugs

CLAS-OM-3778-Extraction-Box-for-Damaged-Glow-Plugs-PRODUCT-
IMG

Product Information

Product Name: OM 3778 Damaged Glow Plug Extraction Set M8-M10

Manufacturer: CLAS

Product Description: The OM 3778 Damaged Glow Plug Extraction Set is designed to remove damaged and broken glow plugs from cylinder heads. It is specifically designed for glow plugs with either a M8 x 1.0 thread or M10 x 1.0 thread. The set includes all necessary adaptors, centring and thread cleaning tools to safely remove the damaged glow plug without damaging the cylinder head.

Product Usage Instructions

Use the dual-size step drill (6) to remove the remains of the connector post / electrode while also removing the threaded portion of the glow plug body. Ensure the drill is kept straight to avoid damaging the threads in the cylinder head. Drill down at least 15mm to remove all of the threaded portion.
Choose either the M8 tap (11) or M10 tap (12) depending on the size of the glow plug. Fit the chosen tap to the provided Ratchet T-Bar (1). Clean out and recut the threaded portion of the cylinder head. Coat the tap in grease for lubrication and to contain the swarf produced.
Take the 1/4 tap and fit it to the provided Ratchet T-Bar (1). Cut a thread in the remaining glow plug body. Again, coat the tap in grease for lubrication and to contain the swarf produced. Cut a full 15mm of thread. The remains of the glow plug body can now be removed.
Screw a puller adaptor mandrel (13) into the 1/4 thread that has just been cut.
Screw on the force screw (3) to the puller adaptor mandrel.
Fit the puller outer housing (3) over the force screw.
Screw on the force nut (3) with the raised collar facing inwards.
Hold the force screw with a 12mm spanner or socket, and wind the force nut down using a 30mm spanner. This action will draw out the remains of the glow plug body free from the cylinder head.
Before fitting the new glow plug, thoroughly clean inside the aperture with a wire brush or similar tool. Make sure to remove all swarf, dirt, and debris from the aperture, glow plug thread, and combustion chamber.

Note: The three taps, two pilot drill centring sleeves, two pilot drills, two dual-size step drills, and two puller adaptor mandrels are considered consumable and are not covered by guarantee. Replacement parts are available.

WARNING

Before returning this product for any reason (installation problem, instructions for use, breakdown, manufacturing problem…), please contact us.

Contact

You can reach us by mail sav@clas.com or by phone +33(0)4 79 72 69 18 or go directly to our website clas.com
If you have changed your mind regarding your purchase, please return this product before you attempt to install it.

GLOW PLUG REMOVAL SET

For removing damaged and broken glow plugs from cylinder heads, specifically where they have sheared off just under the hex flush with the cylinder head.
Suitable for glow plugs with either a M8 x 1.0 thread or M10 x 1.0 thread.
Comprehensive set includes all necessary adaptors, centring and thread cleaning tools to safely remove the damaged glow plug without damaging the cylinder head.

CLAS-OM-3778-Extraction-Box-for-Damaged-Glow-Plugs-
FIG-1

SA 5340: RATCHET
SA 5342: DRILL HOLDER
SA 5345: CONICAL EXTRACTOR WITH SCREW
SA 5346: TORX SOCKET E10 3/8″
ALLEN KEY
SA 5333: STEP DRILL Ø4-9mm
SA 5332: STEP DRILL Ø4.2-7mm
SA 5328: PILOT DRILL CENTERING SLEEVE
SA 5341: Ø3.5mm DRILL
SA 5337: TAP 1/4″ D.-28
SA 5336: TAP M8x1
SA 5335: TAP M10x1
SA 5334: FORCE SCREW

BEFORE STARTING

We strongly recommend that the cylinder head is removed from the engine before work is commenced.
If cylinder head is to be left in situ, then remove the relevant injector and connect an air-line via a suitable adaptor to ensure metal swarf and dirt cannot enter the combustion chamber.
Maintain tools in a good and clean condition.
Keep well lubricated. Lubricate thread cutting taps with thick machine oil or grease.
Where correct eye protection, particularly when cleaning any swarf away from engine.
When finished, account for all tools and parts being used. Do not leave them in or near the engine. Return all parts to the case and store in a safe, dry place.

Cautions

Wear suitable eye protection.
DO NOT USE AIR TOOLS WITH THIS PRODUCT.

INSTRUCTIONS

CLAS-OM-3778-Extraction-Box-for-Damaged-Glow-Plugs-
FIG-2

Push-fit Top Connection Removal Tool star socket (4) onto top of glow plug. It may need to be tapped on gently with a hammer.
Using a 3/8” ratchet handle, turn clockwise to break off the top part of the glow plug.
Note: When top portion of glow plug breaks, it may also shear off the inner glow plug electrode. If the inner electrode does not break, it can be withdrawn completely from the glow plug body. In this case go straight to point 5. If the inner electrode does shear off, then continue to point 3.
Position Centring Sleeve (8) onto remains of glow plug. It may need to be tapped on.
Using 3.5mm pilot drill (9) drill a pilot hole into remains of connector post / electrode. Drill down at least 15mm past uppermost part of the glow plug body.
Fit either M8 (6) or M10 (7) dual-size stepped drill (depending on size of glow plug) to the drill holding adaptor (2). Secure stepped drill into adaptor by tightening the grub screw with Allen key (5) provided, ensuring the grub screw acts on the flat on the shank of the stepped drill. Fit the drill holding adaptor to chuck of power drill and drill out remains of connector post / electrode and threaded portion of glow plug body.
Care Point: The dual-size step drill allows removal of the remains of the c onnector post / electrode while also removing the threaded portion of the glow plug body. Take care to keep the drill straight so that the threads in the cylinder head are not damaged. Drill down again at least 15mm to remove all of threaded portion.
Take either M8 (11) or M10 (12) tap (depending on size of glow plug) and fit to Ratchet T-Bar provided (1). Clean out / recut the threaded portion of cylinder head. Coat the tap in grease to lubricate and also contain the swarf produced.
Take the 1/4” tap and fit to Ratchet T-Bar provided (1). Cut a thread in the remaining glow plug body. Again coat the tap in grease to lubricate and also contain the swarf produced. Cut a full 15mm of thread. The remains of the glow plug body can now be removed.
Screw a puller adaptor mandrel (13) into the 1/4” thread that has just been cut.
Screw on the force screw (3) to the puller adaptor mandrel.
Fit the puller outer housing (3) over the force screw.
Screw on the force nut (3) with raised collar facing inwards.
Holding the force screw with a 12mm spanner or socket, wind teh force nut down (30mm spanner). This action will draw out the remains of the glow plug body free from the cylinder head.
Before fitting the new glow plug, thoroughly clean inside the aperture with a wire brush or similar. Ensure that all swarf, dirt and debris is removed from aperture, glow plug thread and combustion chamber before fitting new glow plug.

Note: Due to the nature of the task and tools, the three taps, two pilot drill centring sleeves, two pilot drills, two dual-size step drills and two puller adaptor mandrels are regarded as consumable and not therefore covered by guarantee. (Replacement parts are available.)

CLAS Equipements