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  #46  
Old 01-08-2016, 07:37 AM
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On the OM617, inspect the C.C. area very closely. They are prone to cracking in the narrow area between the valves and the injector receiver.

Will Hunter on this board has a link showing the problem areas.
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  #47  
Old 01-08-2016, 07:17 PM
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Quote:
Originally Posted by acb70 View Post
I'm going to be doing this job on a 617 very soon, glad to see someone else is jumping into the head gasket project as well! Good luck!
Thanks!
Best of luck to you too,I just ordered a actual
straight edge off eBay for $25 it's a 24" one which should be perfect. The ruler bends too much for me to have 100% trust in it.
The other thing I have to check is if the block is warped,if it is I wonder if at that point I should just write the whole motor off..
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  #48  
Old 01-09-2016, 09:12 AM
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Not likely for the block to warp it is cast iron on that engine. The head is aluminum which will warp if overheated and especially if not properly torqued.

You could always take the head to a machine shop and have them give it a quick look to see if it is worth saving.
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  #49  
Old 01-09-2016, 10:13 PM
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Quote:
Originally Posted by jay_bob View Post
Not likely for the block to warp it is cast iron on that engine. The head is aluminum which will warp if overheated and especially if not properly torqued.

You could always take the head to a machine shop and have them give it a quick look to see if it is worth saving.
Right on,I hope the heads not too far gone everytime I look at the price of these engines it makes me a little queezy lol.. I saw where one online vendor wanted $9000 for a rebuilt OM602! If that's not a shot in the pants I don't know what is . I found a few vendors on car-part.com in the $1200-1600 range but even then I can exceed the cars value rather quickly, so as always I've got my fingers crossed.
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  #50  
Old 01-09-2016, 11:56 PM
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Hardly anyone installs rebuilt engines. If you need to, grab one from a junkyard for 200 bucks and drop it in. Done.

If the head is seriously warped, there are ways that it can be torqued and heat cycled to remove the warp. Only slight warping is usually removed by machining. Thicker prechamber seals are needed move the prechamber up away from the piston.

In the piston pics, it looks like you have cavitation damage. Is the piston surface cratered?
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Last edited by mannys9130; 01-10-2016 at 12:08 AM.
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  #51  
Old 01-10-2016, 09:30 AM
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Quote:
Originally Posted by mannys9130 View Post
Hardly anyone installs rebuilt engines. If you need to, grab one from a junkyard for 200 bucks and drop it in. Done.

If the head is seriously warped, there are ways that it can be torqued and heat cycled to remove the warp. Only slight warping is usually removed by machining. Thicker prechamber seals are needed move the prechamber up away from the piston.

In the piston pics, it looks like you have cavitation damage. Is the piston surface cratered?
Yea I've been keeping an eye out for another OM602 in a JY but they're like hens teeth...Ive only seen two OM606's before never a 5cyl,and actually the pistons and cylinder walls look fine,the OM602 has really funny shape pistons,Ill send some close up pics of them after they're cleaned up a bit!
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  #52  
Old 01-10-2016, 10:32 AM
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What are "prechamber seals" Manny? I presume you mean the thicker head gasket Mercedes specs for resurfaced heads (data in the FSM)?

I agree mbolton, I've seen several 603s in the boneyards when harvesting parts for my projects, ... never a 602 or 606 turbo. Fortunately, one pops up on this forum occasionally for parts, if you're on the left coast you have a decent shot at it.

If the engine overheated enough to warp the head severely, it is also possible that being the 602/603 head, you have some cracks in the aluminum. Cracks might be obvious, might not, ... know anyone in the casting industry who might be able to x-ray it for you? Before spending a lot on machining and rebuilding the head you should have it thoroughly inspected.
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Last edited by babymog; 01-10-2016 at 10:43 AM.
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  #53  
Old 01-10-2016, 01:54 PM
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IIRC there are $pacer$ available for the 601/2/3 to set prechamber protrusion, in addition to the thicker head ga$ket you mention.

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  #54  
Old 01-10-2016, 03:08 PM
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Is this for use when the prechamber seat has been machined?
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  #55  
Old 01-10-2016, 09:43 PM
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Picture of pistons as promised,talk about a crazy shape!

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  #56  
Old 01-10-2016, 09:50 PM
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You might already have noticed that the head is flat with the prechamber protruding into the cylinder area, and the pistons stand proud of the block at TDC.

Had to make clearance somewhere for the prechamber! I agree, the pistons have an odd surface.

Stranger below, the oil squirters spray into the casting as the pistons move, cooling the piston crown.
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  #57  
Old 01-12-2016, 10:47 AM
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Indeed,
well good news is the straight edge showed up today,bad news is well..see the pics lol thats the max amount I could get a feeler gauge in,it was better than I thought actually.. So is this going to require machining?



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  #58  
Old 01-12-2016, 10:49 AM
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Another thing to note,is that it's only warped right in the area where the headbolts were loose,right near the IP.
Also .006mm is the smallest feeler gauge on that set,with .008mm being the second smallest.
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  #59  
Old 01-12-2016, 12:21 PM
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To rest the trueness of your steel ruler just reverse it to it's other edge.. I suspect you knew this. Same reading your golden. Two different readings you can average them.

My guess and it is only a guess that combustion escaping and driving coolant out of the area. Allowed the head in that area you find warped to get very hot. So hot it may have let the metal collapse a little and that is the reason you found the loose head bolts.

The whole engine may not have overheated to enable this. Generally described as a hot spot where coolant is driven away from the location.

The reason actually it does no harm coming off the highway. To let the engine run for a minute or two before shutting down. Reduces possible thermal stress on the casting. This occurs when there is too much temperature difference between parts of the casting.

I have suspected for a long time that if you practice this delayed shut down on a 603 with the number fourteen head. It may last a lot longer. It certainly will do no harm if practiced.

Also I think I would employ a water wetter if I owned one of those heads. Or any Mercedes diesel with an alloy head.

The area of issue on your head has undergone a lot of thermal stress and should be checked for cracks in the area. Also do not exceed the maximum of head material removal as it is limited on these heads. A thicker compensating head gasket may be available. This could allow a little more material removal than allowed or make up for the amount of material removed. This also might mean your may not have to shim your pre chambers.

Although they will have to be removed for milling the head. The break you may be getting depending on the last owner is the rest of the head may be flat.

I have purchased cars where the owner shut the car off when all the coolant was blown out. On a couple where they continued driving the head was warped beyond sensible salvation. Last but not least make sure that wherever you take the head knows what they are doing. Usually asking any local Mercedes dealer where they send theirs out to is fairly reliable. Or even an independent mechanic that does a lot of Mercedes. If nothing else they know where not to send them.
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  #60  
Old 01-12-2016, 01:15 PM
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Quote:
Originally Posted by barry12345 View Post
To rest the trueness of your steel ruler just reverse it to it's other edge.. I suspect you knew this. Same reading your golden. Two different readings you can average them.

My guess and it is only a guess that combustion escaping and driving coolant out of the area. Allowed the head in that area you find warped to get very hot. So hot it may have let the metal collapse a little and that is the reason you found the loose head bolts.

The whole engine may not have overheated to enable this. Generally described as a hot spot where coolant is driven away from the location.

The reason actually it does no harm coming off the highway. To let the engine run for a minute or two before shutting down. Reduces possible thermal stress on the casting. This occurs when there is too much temperature difference between parts of the casting.

I have suspected for a long time that if you practice this delayed shut down on a 603 with the number fourteen head. It may last a lot longer. It certainly will do no harm if practiced.

Also I think I would employ a water wetter if I owned one of those heads. Or any Mercedes diesel with an alloy head.

The area of issue on your head has undergone a lot of thermal stress and should be checked for cracks in the area. Also do not exceed the maximum of head material removal as it is limited on these heads. A thicker compensating head gasket may be available. This could allow a little more material removal than allowed or make up for the amount of material removed. This also might mean your may not have to shim your pre chambers.

Although they will have to be removed for milling the head. The break you may be getting depending on the last owner is the rest of the head may be flat.

I have purchased cars where the owner shut the car off when all the coolant was blown out. On a couple where they continued driving the head was warped beyond sensible salvation. Last but not least make sure that wherever you take the head knows what they are doing. Usually asking any local Mercedes dealer where they send theirs out to is fairly reliable. Or even an independent mechanic that does a lot of Mercedes. If nothing else they know where not to send them.
Thank you for the advice Barry,that's reassuring.
I read on a Sprinter forum (they have the same OM602 engine apparently) that the FSM says the maximum allowed gap is 0.008mm,I just re-checked the gap and mine is actually this:


0.012mm! sorry for the blurry pic

I need to see what the maximum safe amount is too skim off the head but it sounds like I may be able to get away with a light .004mm skim and be in spec,on a other note I may of just sourced another engine on the cheap..We shall see
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