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  #1  
Old 10-25-2008, 12:47 AM
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R&R OM-603 Cylinder Head

The turbo oil seal was leaking on my 1991 350 SD. Turbo and manifold was removed and I discovered the exhaust stud nearest the firewall was broken off about 3mm below the surface. I can't seem to remove the stud with a screw extractor. There's a 1/8" hole drilled into the center of the broken stud and the stud actually rotated and bottomed into the tapped hole while drilling with a right handed bit. Now I think removing the head is my only option. Can someone provide instructions (or a link) to remove and replace the head?

Thanks in advance.

Greg

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  #2  
Old 10-25-2008, 05:53 AM
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I'd recommend you get a left handed drill bit in a slightly larger size than the existing hole and try that. If the broken part moves in, it will probaly come right out.
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  #3  
Old 10-25-2008, 10:10 AM
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Quote:
Originally Posted by maxbumpo View Post
i'd recommend you get a left handed drill bit in a slightly larger size than the existing hole and try that. If the broken part moves in, it will probaly come right out.
x 2
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  #4  
Old 10-25-2008, 10:38 AM
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First drop some Kroil down the stud's remains. Then go to a easy out.
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  #5  
Old 10-25-2008, 04:26 PM
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Thanks for the encouraging feedback.

In the event that a screw extractor doesn't work, does anyone have the head R&R procedure? The engine has accumulated 202,000 miles and I'd be interested in looking at the cylinder bores and checking for potential connecting rod bending.

Greg
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  #6  
Old 10-25-2008, 05:06 PM
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head removal...

The camshaft is the key to removing the head ....There is a proceedure for that ...whats your location??
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  #7  
Old 10-25-2008, 06:13 PM
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Since nobody's biting, ... open the hood, ...

Special tools you'll need are some rubber/plastic caps, 12 of 'em, to keep the injectors and injection pump outlets really clean, best to get some good ones from the local hardware store before you start, a nice deep 27mm socket for the injectors, a selection of allen-wrenches/bits including (I believe) a 5.5mm for the difficult to remove ones around the turbo, and a wobble-extension for the socket-head bolts holding the intake manifold. If you're replacing the timing chain, you'll need a chain breaker and chain rivet tool, if you're leaving the chain on then you won't, but you will then need a puller for the upper chain guide pin (the one that sticks out of the upper belt-tensioner shock mount). Triple-square bit for head bolts, long one is preferred to leave the cam in place.

Set the engine at TDC.

Drain coolant from the engine.

Take pictures of the wiring to the sensors and soft fuel lines on the head and remove the wires.

Remove the air filter, and then the heat-shield between the engine and filter area. This makes turbo and exhaust manifold removal much easier. Get the exhaust pipe knocked off of the turbo outlet early in the game with the turbo still attached so that you have something to work against, worked better that way for me.

Remove the belt tensioner shock/spring and upper mount from the head.

Remove the upper radiator hose, remove the heater hose from the rear of the head.

Remove hard fuel lines, intake crossover tube, intake manifold. Remove turbo, don't forget about the oil-return line from the bottom of the turbo to the lower part of the block. Remove exhaust manifold.

Remove Glow-Plug Wires.

Remove the cam-cover. Ensure that the timing marks are at TDC.

Remove the timing chain tensioner: It is on the passenger side, about half-way down, remove the large nut not the smaller one, you want to pull the whole thing out.

If you are leaving the timing chain on the engine, zip-tie the chain to the timing gear, remove the bolt from the end of the camshaft and lay the gear in the opening.

Pull the pin forward-out of the head that holds the upper end of the chain guide, remove pin and guide. The pin removal "requires" a slide-hammer, many of us have done it with a bolt and washers or other method. If yours is really stuck, can be a problem.

If you have the long triple-square bit for the head bolts, you can start to unbolt the head now as it will reach the head bolts under the cam towers (all-the-way through). If the shorter one, then you'll need to remove the camshaft first.

If camshaft, consult the proper bolt loosening/removal sequence so that you don't risk breaking the camshaft, and remove the camshaft. The bearing caps for the camshaft are numbered, but not the lifters. If you're re-using the lifters it is best to mark them now to ensure that they don't get mixed-up.

If you're going to remove the injectors, IMO this is a good time while the car is holding the head in place, makes it easier to turn the injectors. Same thing with the pre-chambers, this is a good time to break the lock-rings free (special tool, not mentioned above).

If removing the head bolts now, consult the FSM for the proper sequence to lessen the possibility of cracking or warping the head.


I'm sure I left some things out, and hopeful that someone will come and add them in now that there is a start.

Good luck.
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  #8  
Old 10-31-2008, 08:53 PM
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Jeff thanks for the reply. This job doesn't appear to be too bad. I'm concerned about getting the timing correct when it's time to reassemble. Last year, I put in new injector nozzles and pintles and also pulled all the pre-chambers, cleaned and reinstalled. I don't want to pull them again if it isn't necessary. If I remove the head, what parts would you guys recommend changing? Timing chain, guides, any other parts? The engine now has 202,000 miles.

Anthony, I'm located in central New Jersey.

I look forward to any additional input.

Greg
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  #9  
Old 10-31-2008, 09:46 PM
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Talking

Quote:
Originally Posted by Maxbumpo View Post
I'd recommend you get a left handed drill bit in a slightly larger size than the existing hole and try that. If the broken part moves in, it will probaly come right out.

X3

I think the left hand bits have only failed me once out of at least 30 tries.
But don't forget to put your drill in reverse mode!
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  #10  
Old 10-31-2008, 09:49 PM
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Charles,

I have a 1/8" hole in the stud at this point. What size L.H. bit do you recommend?

Greg
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  #11  
Old 11-01-2008, 06:39 PM
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Greg ...contact me if you need help..
I have a set of easy outs...
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  #12  
Old 11-02-2008, 10:04 AM
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Where are you guys located?? Im in Wall (exit 98)
Im going to have to tackle a head gasket in a 350 sdl ( I hope thats all) in the next few weeks.
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  #13  
Old 11-07-2008, 09:08 PM
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Rick,

I live in New Brunswick. I'm going to try one more time to remove the broken stud without pulling the head. If unsuccessful, it will be time to round up the pin puller and special tool to remove head bolts. Do you have a manual for this engine? PM me to coordinate.

Greg
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  #14  
Old 11-08-2008, 10:32 AM
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Greg, Ive got the factory manual. Im about 30 minutes south on rt 18 in Wall. If you want to drive down and borrow the manual you're welcome to. I can lend a hand depending when you need one. Im an airline pilot, and don't have a real regular schedule, and most of the time I am just on call....so I could help out, just know that I might have to leave when the phone rings. I'll pm you#
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  #15  
Old 12-05-2008, 06:08 PM
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Replacing Cylinder Head on OM603

I will be replacing the cylinder head on a '91 350 SD soon. An engine rebuilder familiar with this engine suggested that I drain the oil from the hydraulic lifters. He claims there is a possiblity that the lifter plunger might inadvertently extend (due to the internal lifter spring force) and the travel of the valve could initially be too deep into the head (making contact with the piston). He also stated that returning the lifters to the original locations is not followed in his shop.

I have not seen this draining procedure in any of the cylinder head R&R instructions. Anyone have an opinion in this?

Greg

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