I need some guidance on removing the heads on my 97 PSD I have the injectors out and was going to do a compression test after replacing the injector orings but one of the glowplugs broke in the head. I've fought soaked and fought more, but can't get it out. I have decided to pull the heads and while I have them off get them worked... I need to get my truck back on the road soon so all help is greatly appreciated.
Thanks in advance!

 

About the only guidance for removing the heads that I can give you would be to use a hoist or have someone else help you pull them out of the engine bay. They are HEAVY. The other thing to do is to keep the pushrods and such organized in such a way that they can be reinstalled in the same positions from where they were removed. For this I usually sacrifice a cardboard box. Tape the box shut, and then drawn an engine on it or put an arrow so you know which way is the front and then poke holes into the box and stick the pushrods and such into the holes so you can keep them in order. I don't know if the stock bolts are torque to yield or not (I doubt they are) but if they are you will need to replace them.

I don't know if you have increased power aspirations for the engine I would really think about a set of head studs and a set of Comp 910 valve springs as well as some upgraded push rods for the engine. If you're looking to stay mostly stock, then that is money you don't have to spend. Also, I would seriously consider having the injector cups replaced while the head is out. It is not that expensive and it will be a ton easier to do with the heads on the bench.

Have the heads decked, but I wouldn't bother with any porting or anything like that. It just isn't really worth the time and effort on a turbo charged engine.

I am making the assumption that some of this is stuff you already know since you don't seem reluctant to pull the heads off, but if not, I would suggest you go to the library and get the print out from a service manual that gives you step by step directions and has all the torque specs. There may also be a good write up available from someone on here, but I am unsure. Torque specs and sequence are very important on head bolts so don't take that part lightly.

Also, for what it is worth, some guys have been able to remove the broken tips of those glow plugs without pulling the heads. If that is still an option, it would save you a lot of time and some money. Head gaskets aren't cheap, you know?

 

I have tried several sprays liquid wrench and another couple but all I managed to do is break a brand new pair of needle nose vicegrips .. I have tried all that I can think of with an exception of cramming the thing to "blow" it out... I actually know little about mechanics.... I just can't afford $1000 for someone to do it for me. I know nothing about taking them off...

 

If that is the case, I think I would try everything I could to get that thing out without pulling the heads. It isn't a hard job, but it isn't cheap either and you're going to need a torque wrench at minimum.

Some guys have had luck cranking the engine over and blowing the broken tip out. Just be sure you pull fuse 22 under the hood, or disconnect the CPS or something so you aren't spraying fuel and actually trying to start the engine. I am sure other will come along who have had more experience removing these things when they're stuck in the head.

 

I have a ton of tools and a shop "@ home" just little knowledge...

 

Hmmmm, head removal.... I hear that a guillotine works well.

 

Is there enough flat surface to get a pilot drill started and use an easy out ?

 

Have you tried a slide hammer yet?

 

Super price on KD Tools 2290 at ToolTopia.com

 

#8 cylinder no room for a drill or slide hammer...

 

I'd try what Nate said and pull fuse 22 and such and turn it over. Sometimes there will be enough force to drive it out. Just close the hood so it doesn't break a window!

 

Do I need to put the vc back on?

 

Or the injectors?

 

I would stuff rags in your injector holes also, if you turn it over. Who knows where that glowplug tip will end up.

 

If you try that put some visegrips on it so it can't get sucked in to the engine.

I tried it when mine broke off in the head and it didn't work. It took me 4 hours to get mine out