An additional way to check valve seating would be to fill the ports from the back with diesel fuel and check for seepage on the cylinder side.

Are there any dowel pins or protuberences on the block to help keep your headgasket from sliding around when you reinstall it?

Another forum you may want to check out for your P-car would be the one on Rennlist. It's pretty active and provided me with lots of info for my 993.

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2005 Pathfinder LE
2001 E55
1998 M3
1982 320i

Gota love that light, 4 valve per cyilnder, dohc, diesel engine looks like fun!

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Have you ever noticed that anybody driving slower than you is an idiot, and anyone going faster than you is a maniac?

As long as they would add one additional commandment for you to keep thy religion to thyself.
George Carlin (Wonder where he is now..)

1981 240d (engine donor 1983 240d) recently rebuilt engine hurray! - No more.. fought a tree and the tree won.

pearl black 1983 240d 4speed (Converted!@$$%) atleast the tranny was rebuilt.

14 Jan 08 update:

Engine is mostly reassembled.

- Used brand new cyl head bolts.
- Replaced all the coolant hoses and the tstat.
- New intake and exhaust manifold gaskets.
- New oil filter housing gasket and O rings.
- Cleaned up the ground strap and elec connections for the starter (you have to remove the starter to remove the oil filter housing )

Right now I'm just waiting for the new injector nozzles to come in. I'm going to have the shop install them and set the proper pop pressure.

Also I'm looking around for a local machine shop to clean the intake manifold and crossover pipe. I have them stripped (flaps, ccv tubes, etc are all removed) and waiting for cleaning. I'll post some before and after pics - that manifold is *nasty* with > 50% blockage on some of the ports.

This thing should run like a top once it's all back together.

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'98 E300 turbodiesel

This is why I did the CCV mod a few years prior. Good to hear it's coming back together nicely!

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#dieselFLEET
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'97 E300
'99 E300

Get 5 gallons of kerosene and a dump it into a tub, deap enough to submerge the manifold. Let it soak and use pipe cleaners to knock the crap lose. I know some guys use B100 but I have no idea where to buy that.

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2016 Corvette Stingray 2LT
1969 280SE
2023 Ram 1500
2007 Tiara 3200

I've used B100 to soak VW TDI manifolds and it works well. I don't have a tub large enough for this huge 606 manifold though. Plus, I recall it being a particularly nasty dirty job to clean these things, so I'd much rather pay a machine shop $80 to hot tank it for me.

I have the official MB service DVD for the 210 platform, that's what I've been using this whole time to do the job. If this is something different, I may be interested, otherwise I think I have what I need (but thx tho!!)

I have all new CCV hoses and nipple pieces and whatnot that will go in after the intake cleaning.

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'98 E300 turbodiesel

I found the thread here about CCV mod on the 606.962 but I haven't seen one for the 606.912. Do you have a link?

Even better would be an EGR mod. I don't mind the oil vapors nearly as much as that pesky soot.

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'98 E300 turbodiesel

For $80 I'd pay someone to do it as well!

Are you going to do the EGR mod and kill it while its apart? How do your intake valves look? On my 603 they looked nasty, the EGR has been gone for 4 years and they still are pretty dirty.

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2016 Corvette Stingray 2LT
1969 280SE
2023 Ram 1500
2007 Tiara 3200

ReRouting CCV lines on E300 [NON-Turbo]

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#dieselFLEET
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'97 E300
'99 E300

If you need a pdf of the 605-606 manual, I can email 10MB of it at a time...

Maybe find a vender to reface the mating surface (A MUST) they'd most likely have a hot tank for the parts washing up project.

606 016 00 81 for the intake vent fittings.

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Mark
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THE WHITE FLEET
2016 GLE300d 4-MATIC 38K BROWN!
2012 S350 Bluetec==94k WHITE

2007 ML320 CDI==166K WHITE (FOR SALE)

Under new management:
2005 E320 CDI--140K--WHITE
1995 E300-Diesel-133.5K--THE CAR IS BLUE
1986 300SL--97.5K (European) AND WHITE. Back in Europe!
1991 190E 2.3-73K California Perfect.--WHITE
1995 E320-Wagon-159K--WHITE (recently scrapped)
1987 300D Turbo-213K--WHITE
1987 190D 2.5 Turbo-288K--WHITE

You're good then, I have the MB 124 DVD that details the 605-606--I'm sure it's the same.

It's nice to see such quality questions and observations on your part. Your process is impressive.

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Mark
========
THE WHITE FLEET
2016 GLE300d 4-MATIC 38K BROWN!
2012 S350 Bluetec==94k WHITE

2007 ML320 CDI==166K WHITE (FOR SALE)

Under new management:
2005 E320 CDI--140K--WHITE
1995 E300-Diesel-133.5K--THE CAR IS BLUE
1986 300SL--97.5K (European) AND WHITE. Back in Europe!
1991 190E 2.3-73K California Perfect.--WHITE
1995 E320-Wagon-159K--WHITE (recently scrapped)
1987 300D Turbo-213K--WHITE
1987 190D 2.5 Turbo-288K--WHITE

I'm hoping I don't have to pull the head on my '95 but with this write up it's not quite as intimidating now!
Which service DVD did you get? I'm not satisfied with the ones I bought from an ebay seller.

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95 E300 Diesel 265k and counting

Lupin,

How are those Bosio injectors working out?

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#dieselFLEET
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'97 E300
'99 E300

Great! Small but noticeable power improvement over the originals, although that's probably more due to the originals being worn out than anything else.

Have higher performance Bosio nozzles on 2 of our 3 VW TDI's as well and love em.

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'98 E300 turbodiesel