I just bought a 98 E300. I put over 2500 miles on it already. I love it. It just started giving me trouble starting. If I wait longer before cranking it helps. I suspect it needs new plugs. It looks like the intake manifold needs to come off. I havnt got any books yet for it but can anyone tell me if manifold removal is straight forward or are the things I need to know ? Is glow plug removal as simple as it seems also ? I own and work on a Nissan SD33 diesel (for sale) and a 6.2 Chevy diesel but this is my first Mercedes so I would be gratefull for any tips

Scott

Search "606 + siezed glow plug" and variants first..... search lots, learn lots, be careful and go slow.

There is a DIY above that describes the removal of the IM and an "uneventful" GP change.

If you've got a bad GP or relay it ought to light up the GP light.

If it is simply more difficult to start, it is more than likely a fuel/air leak.

Define which.

*edit* It would be helpful if you spelled it correctly first "SEIZED".

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

Thanks, will do. It is just simply harder to start. Air could well be the problem. will you get a glow plug light if a couple of plugs are inop ?

sounds like you have an air leak.

Look at the clear palstic fuel lines while its running with a bright light and look for bubbles. Even lil ones.

The trick is to identify in which line they first appear.

The fuel path is as follows: from tank into fuel thermo in the cly head, then to top of pre-filter, out bottom of pre-filter to shutoff valve (SOV), out bottom of SOV to end of lift pump, out lift pump to main filter, out main filter to SOV and finally into IP. Detail http://www.detali.ru/cat/oem_mb2.asp?TP=1&F=210025&M=606%2E962&GA=722%2E608&CT=M&cat=19T&SID=07&SGR=120&SGN=04

Find which line has air and then look at the seal(S) prior to that point. Usually is prior to fuel exiting the lift pump as it is suction to that point. Check the Delivery valve seals on top of the IP too.

Each line is sealed with an oring. Sizes are here OM606.962 o-ring size or buy "viton" orings from fryerpower.com.

The white horseshoe clips on the ends of the fuel lines are spreaders; push them tightly closed for removal, loosen them to seal.

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

You should be able to check your glow plugs with an Ohmmeter without having to remove anything but the connector that goes to the Glow Plug wires at the. (The Diesel Giant site has a trouble shooting pictorial for 617 engines but enough of it is close enough to be helpful.)


Your Glow Plug Relay may look different but the connector on the left of the pic is for the Glow Plug Wires and they are numbered per cylinder.

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84 300D, 82 Volvo 244Gl Diesel

You can even use a test light between a 12v + source and the GP. If the GP is completely dead, you won't get a ground off of it.

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Jake
1999 e300d PlantDrive WVO/SVO conversion
**note to self: oil changed at 268k kms**
1990 Toyota 4Runner FrankenDiesel swap

I have a 96 non turbo model, but once you get to the glow plugs, as mentioned, take your time and be patient. When I did mine, every one of them was carbon bound, and I ended up using about 3 cans of PB Blaster, and a product called Freeze-Off, both of which can be obtained at most auto supply stores. The other thing to get a six sided socket rather than a 12. This seems to get a better grip on the plug without rounding it off. I would suggest spraying down the plugs the night before you plan to do the job, and then use a torque wrench to try and get them out. The shearing point of the plugs are in the neighborhood of 45 N/M, and the torque wrench will enable you to stay within that limit. Some posters have advised warming up the engine before you attempt to remove the plugs, but that is up to you. Prior to installing the new plugs, it is best to get yourself the proper reamer to ream out the holes to insure that most of the carbon is removed.

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96 E300d