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  #1  
Old 07-04-2018, 07:50 PM
Saturnfan's Avatar
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OM606 Cylinder Head Tools

-I recently bought a 1996 E300D. I'm somewhat new to the W210 chassis, and this is my first OM606 engine. The car is hard to start, and compression is leaking passed several of the valves. Once I commit to removing the cylinder head, I want to be sure I have the needed tools to dismantle it!
-I have the special tools for engine work on the OM615, OM616, and OM617 engines. The fuel injectors, prechambers, and the rings that hold them in are completely different. I've seen conflicting information on what tools will work, and what will not. What specifically should I look for, and where?
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  #2  
Old 07-05-2018, 03:11 AM
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I just replaced the head on my 1999 e300d it's just the turbo version but all internals are identical. The only couple special tools I needed were a crank lock via starter ring, a special star bit for the head bolts, some etorx sockets, a stubby 8mm allan key socket for the fan clutch bolt, a good valve keeper remover/installer, and a whole lot of Metric sockets from 32mm down to 7 mm I belive. For the pre chambers you will need a different size tool I belive, they sell it here at pelican parts. I used a site called alldatadiy.com and purchased a 1 year subscription for 15 bucks. It just copied everything from the FSM. It worked like a charm for me. Be ready to spend a good amount on replacement parts, and "while you are in there" parts, excluding the head, I easily spent over $700. But it's a heck of alot cheaper than paying someone else to do the job. If you got questions I can help (except for the intake and exhaust manifolds)
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1999 E300D OM606, 278,000 km (Daily)
1984 Camry Turbo-D, 319,000 mi (Sold)
1992 300D OM602, ~450,000 mi (Sold, Blown Head)
1999 F250 7.3 Powerstroke, 243,000 mi (Sold)
1996 VW Passat TDI 110,000 mi (Sold) "The first Diesel"
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  #3  
Old 07-05-2018, 09:50 AM
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..only bit to add would be glow plug reamer, these can be purchased or made from old glow plugs - below is my ..errr attempt lol

Despite it's appearance, the end result wasn't too bad.

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1996 Mercedes S124 E300TD - 129k - rolling restoration project -

1998 Mercedes W210 300TD - 118k (assimilated into above vehicle)
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Old 07-05-2018, 11:32 PM
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Thanks for the responses. I have a pretty extensive tool collection, including the XZN "Triple Squares." I'm more concerned about the pre-combustion chamber tools. Do the ones for OM602 or OM603 work, or are they different? Where would I get these splined sockets and the extractor? I've found conflicting information about what works and what won't.
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  #5  
Old 07-06-2018, 12:09 AM
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You don't need an extractor for the glow plugs. You need an air compressor and an impact gun. The prechamber can be taken out using a slide hammer... That's how the manual recommends anyway.
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Old 07-06-2018, 01:25 AM
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Quote:
Originally Posted by Saturnfan View Post
Thanks for the responses. I have a pretty extensive tool collection, including the XZN "Triple Squares." I'm more concerned about the pre-combustion chamber tools. Do the ones for OM602 or OM603 work, or are they different? Where would I get these splined sockets and the extractor? I've found conflicting information about what works and what won't.
The pre-chambers have a splined collar which comes out using



You then need a heavily weighted sliding hammer with correct thread, not sure about previous version compatibility.
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1996 Mercedes S124 E300TD - 129k - rolling restoration project -

1998 Mercedes W210 300TD - 118k (assimilated into above vehicle)
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  #7  
Old 07-08-2018, 11:59 PM
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It looks like I'll have to find a few tools specific to this engine family.


604 589 01 09 00
602 589 00 33 02
I'll need the socket to screw out the collar that retains the prechamber, and the threaded adapter for a slide hammer to actually extract it. The size and thread pitch is completely different from the tools I've used on the earlier engines.
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Old 07-09-2018, 07:17 AM
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Quote:
Originally Posted by Saturnfan View Post
-I recently bought a 1996 E300D. I'm somewhat new to the W210 chassis, and this is my first OM606 engine. The car is hard to start, and compression is leaking passed several of the valves.

Did you do a cylinder leak down test to determine this?
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  #9  
Old 07-09-2018, 04:00 PM
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Quote:
Originally Posted by Saturnfan View Post
It looks like I'll have to find a few tools specific to this engine family.


604 589 01 09 00
602 589 00 33 02
I'll need the socket to screw out the collar that retains the prechamber, and the threaded adapter for a slide hammer to actually extract it. The size and thread pitch is completely different from the tools I've used on the earlier engines.

The socket is not expensive, here in UK around $20 or less, for sliding hammer, get a shop to adapt an old injector body -

If this is not practical you can use a bolt, thread is fine pitch metric.
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1996 Mercedes S124 E300TD - 129k - rolling restoration project -

1998 Mercedes W210 300TD - 118k (assimilated into above vehicle)
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  #10  
Old 07-11-2018, 01:51 AM
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I'm sure I'll have to purchase the special socket for the collar. You're right that I could use a spare fuel injector as the threaded portion for the extractor. I remember when I made the extractor for my first OM 615. There was a particular bicycle tool that I cannibalized due to it having the correct threads on it!
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