606 Head Gasket Job -part & tool list
 

Fellas,
I'm going to be doing the headgasket on my 99' E300 over 4th of July vacation. I've been doing research on the website and found various member posts containing valuable information. The one thing I cannot find is a complete list of parts. Many parts are listed in the various posts, but I'm piece-mailing everything together. I wanted to post my list here and then hopefully have other members chime in on parts, and their numbers, needed to complete this job. Maybe it could be something for the Wiki if it gets completed?
Any help on adding to my list of parts is truly appreciated. Also, any "while you're in there (injector test, glow plug replacements planned)" additional project suggestions are appreciated.
Part List:
Cylinder Head Gasket Kit (head gasket, intake manifold gasket, exhaust manifold gasket, O-rings for "bushes" of the trim cover, fuel injector heat shields, six O-rings that seal between the top of the cylinder head and the camshaft housing)
Fastlane Part # W0133-1717655

Cylinder Head Bolts
10 x 102mm (20 count)
Fastlane # W0133-1641814
10 x 115mm (6 count)
Fastlane # W0133-1642393

Fabric Fuel Hose
A 605 078 05 81 (count 1)

Stub cap for injector/fuel hose
A 605 070 00 55 (count 1)

Fuel line clips
A 603 078 01 41 (count 7)

EGR to intercooler O-Ring
A 606 997 06 45

Timing Chain Guide Rail Pins
#Part number?

Special Tool List:
Cylinder head lifting brackets (Do I really need these if I have three people to help lift it?)
# 119 589 01 40 00

10mm Triple Square Head Bolt Tool (probably just buy from auto parts store)
#part number?

Injector Removal Tool (I’ll probably just end up using a 22mm deep socket Craftsman)
# Part Number?

Glow Plug Reamer (Trying to get from Diesel 911; otherwise will order from fastlane)
# Part Number?

Glad you mentioned the fuel line clips. Take those off first because they will break into bits and you don't want the bits going into the intake.

Double check on the injector removal. I think I read something a couple weeks ago about them being funky on this engine and a regular socket wouldn't work.

Good tips Rick. Thanks

Does this engine have all those plastic bits that make up the blow-by recovery system? If it does then you will probably have to replace some of those items. Hopefully, you will be able to read the part numbers.

The Most Important Tool You Need
 

The first thing you need is a copy of the factory service manual. It will have a list of all parts needed and all special tools.

That document will pay for itself when you find the allowable specs for reusing the 26 head bolts.

The inj socket is 1/2" drive x 22mm, 4-5/16" long, and has 1/3 of the socket cut away for 2-3/4" (centered on its lenght). Its pretty thin walled too at a hair less than 1-1/8" diameter.

The cutout clears one of the inj return line barbs; the interior of the socket has been milled out somewhat to clear the other.

Part # is 606 589 00 09 00 (the socket is stmped "CW" after the part number).

Greg,
Thank you. Where can I get a copy of this?

This might work.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310327051059&viewitem=&clk_rvr_id=244211153466

I would also do the injector heat shields, the valve cover gasket and the injector well gaskets. There are also a couple plastic rings that hold the rubber fuel lines that will crumble into pieces when touched.

Recommend a high quality 10mm head bolt bit. I just purchased a snap on. Had a Lyle brand twist on first usage, another brand lasted for 28 bolt removals, 26 installations. The failures stopped the project for a week.

Definitely doing the valve cover gasket and pulling my injectors, so I'll be sure to replace those gaskets. Good thought on the 10mm head bolt bit. I'll try to find a source for that.