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Old 07-27-2013, 03:36 PM
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Join Date: Aug 2005
Posts: 56
Any tips/tutorials for 240D head gasket replacement?

Hi, All-

About 6 months ago my 240D started to make a horrible "chuffing" sound while I was driving it. I thought it must be a broken glow plug or something, but I found that the gas was escaping between the head and block on the number 3 cylinder. At night, you can see a small flame there. I parked the car, and have finally got ready to try and fix it.

I can't see anything it could be besides the head gasket, but it is a strange failure mode I haven't heard of before. In any case, I got the head gasket kit, and am about to pull the head and see if that is what is going on.

Does anyone have any tips about doing this? Photos or a tutorial would be great. I have the factory service manual (on CD, ugh).


Max Behensky

1981 Datsun King Cab Diesel pickup
1982 240D 4 speed manual
1987 300TD wagon
1991 300D 2.5 turbo
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Old 07-27-2013, 04:17 PM
Chad300tdt's Avatar
Benzless Scoutmaster
Join Date: May 2007
Location: North Wales, PA
Posts: 4,001
Here's the thread with pics of my 300TD. One extra cylinder, but a similar job.

1985 300TD head gasket repair
2006 Nissan Pathfinder LE
1998 Acura 3.0 CL
"Pleasure in the job puts perfection in the work." - Aristotle (384-322 B.C.)

1985 300TD - Red Dragon
1986 300SDL - Coda
1991 - 300TE
1995 - E320
1985 300CD - Gladys
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Old 07-27-2013, 04:44 PM
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Join Date: Aug 2005
Posts: 56
Thanks for the pointer to your thread

That info is awesome. Thanks so much.
1981 Datsun King Cab Diesel pickup
1982 240D 4 speed manual
1987 300TD wagon
1991 300D 2.5 turbo
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Old 07-28-2013, 09:30 AM
gatorblue92's Avatar
Save the manuals!
Join Date: Jan 2006
Location: Delaware
Posts: 3,407
This thread also has some very good info.

OM616 Overhaul - - Mercedes-Benz Discussion Forum
1977 MB 240D 4 speed 145K - Nearly Perfect
1995 MB E420 197K - Weekend Toy
2020 Subaru Ascent 13k - Wife's DD
2020 Ford F150 3.5 EcoBoost 0K - My DD

1979 MB 280E 90K - Sold
1983 MB 240D 238K - Scrapped
1984 MB 300D 347K? - Sold
1984 MB 300TD Wagon - 188k - Sold
1987 MB 300E 5 speed 258K - Scrapped
1991 MB 300TE 5 speed 276K - Sold
1993 MB 400E 218K - Sold
1993 MB 400E 130K - Sold
1995 MB E320 Wagon 190k - Sold
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Old 07-28-2013, 11:07 AM
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Join Date: Jun 2013
Location: State College PA
Posts: 37
Chads thread is excellent.

Just a week or so ago I replaced the cylinder head on a very overheated 78' non turbo I got my hands on for cheap. The head was cracked around almost every valve, it was nuts. PO was... dumb lol.

My best advice is to get a system of meticulous organization. Box, bag and label everything. I know that is obvious but it's my best advice.

Pulling the little bearing out of the head for the slide rail out was honestly one of the hardest parts. Even with a massive impact it took a lot of PB and repeating. I was starting to think it wasn't going to move.

The job is much easier with an engine hoist and leveler to do the lifting for you, if you have a buddy it's very possible to do it by hand.

Oh and keep tension on the chain at all times, I used a short bungee cord. Can't hurt stuffing a shop towel into the chain valley to prevent sockets from finding their way in there.

Last edited by AwfulMechanic; 07-28-2013 at 12:08 PM.
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Old 08-01-2013, 02:35 PM
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Join Date: Aug 2005
Posts: 56
Hi again, all-

In the factory service manual it has you measure the head bolts to see if they need to be replaced. Some other references I have found suggest that you replace them all, no matter what. I was wondering what you folks thought, since 18 bolts @$6 adds up to around a hundred bucks..


1981 Datsun King Cab Diesel pickup
1982 240D 4 speed manual
1987 300TD wagon
1991 300D 2.5 turbo
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Old 08-01-2013, 06:54 PM
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Join Date: Jul 2008
Location: virginia
Posts: 496
For just a head gasket replace I would measure them and if in spec use them. For a total overhaul get new ones

1977 240D turbo
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