606 head removal - Page 3 - PeachParts Mercedes-Benz Forum

lupin..the..3rd · #31 01-09-2008, 05:58 PM

Quote:

Originally Posted by lupin..the..3rd

Found a diesel injection shop about 15 minutes from home. Dropped the injectors off there to be tested - should have them back with test results tomorrow.

Got them back, one was much worse than the rest. All were a bit on the tired side. Pop pressures were low and spray patterns weren't great.

I'm expecting the new bosio nozzles to arrive this week. I'll have the shop fit the new nozzles and set them to the correct pop pressure.

New coolant hoses arrived today. I'm replacing all of the coolant hoses. "While you're in there" kind of stuff, you know.

Cervan · #32 01-09-2008, 07:50 PM

Gota love that light, 4 valve per cyilnder, dohc, diesel engine

looks like fun!

lupin..the..3rd · #33 01-14-2008, 04:55 PM

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.

michakaveli · #34 01-14-2008, 05:06 PM

Quote:

Originally Posted by lupin..the..3rd

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

Hatterasguy · #35 01-14-2008, 07:18 PM

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.

markg612 · #36 01-14-2008, 08:34 PM

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.

lupin..the..3rd · #37 01-14-2008, 10:06 PM

Quote:

Originally Posted by Hatterasguy

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.

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.

Quote:

Originally Posted by markg612

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

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.

markg612 · #38 01-14-2008, 10:13 PM

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.

lupin..the..3rd · #39 01-14-2008, 10:16 PM

Quote:

Originally Posted by michakaveli

This is why I did the CCV mod a few years prior.

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.

Hatterasguy · #40 01-14-2008, 11:17 PM

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.

michakaveli · #41 01-15-2008, 09:59 AM

Quote:

Originally Posted by lupin..the..3rd

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.

ReRouting CCV lines on E300 [NON-Turbo]

lupin..the..3rd · #42 01-16-2008, 07:35 PM

The slow boat from Italy finally arrived:

Here's some intake photos. first one is the manifold and crossover pipe, stripped and ready for cleaning. Second pic is close-up on one of the more nasty ports. Still haven't found a shop to clean it yet - called a few local machine shops and none will do it.

lupin..the..3rd · #43 01-24-2008, 12:48 AM

Got the injectors back from United Diesel in Alexandria, VA this week. Wow they did a nice job. They disassembled the injector bodies and ultra-sonic cleaned them, installed the new nozzles, and shimmed them up to the correct pop-pressure. They look like new. Highly recommend them if you need any diesel injector work.

I put the cyl head back on with new head gasket. There are 24 head bolts. They have to be torqued in 5 stages. That's 120 separate bolt torqings. My back hurts now from leaning over the motor for all of that.

I got the injectors put back into the head tonight. It requires this funky looking special socket that costs $50.

Bet I'll never have to use it again either. Also bolted the cam tower back on and both cam shafts. I'm replacing all the rubber bits and pieces as I go - there are *eighteen* rubber O-rings just on the cam tower.

The cam bearing caps were all sequence numbered so very easy to get those all back on in the proper position. (Thanks Mercedes!) There's also a little indexing pin on the exhaust cam that ensures you bolt the pulley on in exactly the right position. Very nice. Installed the new chain tensioner as well. I turned the engine over several full rotations by hand, no valve interference so looks like I'm good.

No pics today, forgot my camera.

Tomorrow I drop the intake manifold off at Allied Machine in Falls Church, VA for cleaning. With some luck, I might have this thing up and running before the weekend!

pimpernell · #44 01-24-2008, 11:03 AM

like to thank you for the blow by blow description and pictures regarding your work. Good luck with the rest of your project!!

lupin..the..3rd · #45 01-24-2008, 11:38 PM

Here's a pic of the freshly reassembled top end with injectors installed. The torques on many of these bolt is surprisingly low. According to the MB service DVD:

Cam bearing caps: 15 NM
Cam pulley bolts: 18 NM
Fuel Injectors: 40 NM

But I follow the instructions and hopefully all will be well. Just waiting to get the intake manifold back from the machine shop and it will be ready for a test drive.