I haven't pulled a 606 head but in the 603 there's the oil dipstick tube holder, the cabin heater coolant fitting and the big fuel filter attachment to release before the head comes clean.

Sixto
87 300D

The dip stick tube was removed and the fuel filter assembly has been removed. It seems like its more the passenger side of the head does not want to move and the drivers side will lift up a 1/4" or so. Are there alignment pins that might be holding it on tight?

Still not sure what to do with the oil water cooler, how does that come apart?

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Just off the top of my head I'm thinking the oil cooler comes off with the oil filter housing.

__________________
Jim

Well I am trying to get the oil water cooler and oil filter off and what a PIA. Getting the starter off was a huge pain. Getting to the top bolt was not easy. Now I am triyng to unbolt the oil filter housing with the water cooler attached. There are (4) bolts or screws holding on the oil filter housing. They use socket head cap screws and so far I have stripped out the internal portion of the first cap screw. Why does Mercedes use these kind of fasteners, because they suck.

Now how do I get the screw off? Any ideas? What about the other 3? Will heat help remove the screws since they are torques on pretty good.

This job has really been easy right up to this point, but it really sucks now. There is not good access to these fasteners so honestly I am stuck.

Does alldatadiy.com say to remove the oil filter housing and oil cooler when removing the head? IIRC I've seen blocks with the oil filter housing still attached.

Sixto
87 300D

For the head removal it syas

1. Disconnect engine wiring harness (29) at cylinder head. See: Service and Repair\Procedures
2. Remove oil filter (40). See: Oil Filter Housing\Service and Repair
3. Unbolt fuel filter (70/2) at cylinder head

See: Oil Filter Housing\Service and Repair says

REMOVAL

1. Disconnect ground cable of battery
2. Remove resonance intake manifold. See: Intake Manifold\Service and Repair
3. Remove starter, refer to Starting and Charging.
4. Drain engine oil from the oil filter, refer to Drain Housing and Replace Element.

• • Remove oil filter element so that engine oil flows off into the

1. Drain coolant, refer to Cooling System.
2. Remove oil filter housing (19)

• • Pay attention to dowel sleeves (8). Clean sealing surface free of gasket residues.
  • Replace gasket (9)

1. Unbolt oil-water heat exchanger (14) at oil filter

• • Check O-rings (15), replace if necessary

I was hoping someone who had done this before knew for sure. The head will not come off at this point, at least not by my trying to pick it up by hand.

I am going to try to drill out the bolt head and try an easy out.

I can't believe I did it but I got the bolt out and got the other 3 off and took off the oil filter and oil water cooler as an assembly. The head is still the same, the drivers side is loose and the exhaust side is tight. It must be alignment pins holding it down since there is nothing else. Could the water leak maybe have glued it together? I am going to try to muscle it off. Should I try to pry it off?

For those of you reading this because you may want to do this in the future the hardest part was removing the starter and the oil filter / oil water cooler. I ended up drilling out the bolt and trying an easy out but that did not work so I took a impact chisel and installed a peen head. I took that and used it on the side of the bolt and got it to spin free, kept doing that and until I was able to remove it by hand. I ended up using the same method on the other 3 bolts. All the bolts are ruined but they all came off so I am very happy.

Yeah, the oil filter assembly is a real PITA. I had to invent all manner of allen extensions and work arounds to get the bolts out but I did it.

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

I figured out why the head would not come off, I still had one of the head bolts in. I can't believe it, the bolt was sitting in a pool of oil so you couldn't really see it. The head is now free but I still can't remove it.

It is hung up on the chain guide so I think I need to remove it but I do not know how. Alldatadiy does not have good instructions for this part. I did pull the top pin, the one where you have to make a puller to get it off. I read many post about that one so I was ready for it but other that that pin what else holds the chain guide on. I attached a photo and you can see where I removed the pin but the guide is still installed. A lot of the other post talked about needing to pull the one pin and some other bolts but it is not obvious.

I can't believe that I spend all day today trying to get out oil filter assembly off and I might not have needed to do that. I would bet you that the head would have come off without needing to pull the oil filter assembly. Oh well it's off now.

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Pic helped. Pull vacuum pump off and you will see another pin that needs to be removed to pull guide out. You should be able to leave the tensioner rail in place IIRC. Use caution removing the vacuum pump because the mechanism spring may be loaded up.

__________________
Jim

I think this version of the 606 has a rotary vacuum pump rather than the plunger type where the little wheel rides up and down the sprocket face so no worries about removal.

Just don't turn it when it's off or it'll burp oil all over the place.

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

Pull the next pin you see and then if it still won't come out remove vacuum pump and see if it comes loose. I've got a drawing around here somewhere I'm looking for to post.

__________________
Jim

I got it off. There is a pin right under the radiator hose connection / inlet of the head. The hole was actually covered with grease but it's a pin just like the upper one only not as long. You have to remove it just like the other one using a puller of some kind. It is officially off.

Now to get the injectors and head checked.

I broke one of the glow plug connectors while removing them so does anybody know if it's a big deal to replace, can I just order a new connector from the dealer and re-solder it on. The whole connector is broke so all I have are 2 wires soldered together.

Most of the harness connectors are serviceable. The plastic is probably just a jacket that snaps on and it should have a part number on it. I'll check my software to see if it shows a part number.

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

Typical practice is to remove head bolts in reverse of tightening sequence. I loosen them a little at a time. Keeping to the sequence ensures you don't miss a bolt or unduly stress the head.

Sixto
87 300D