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  #1  
Old 02-15-2009, 07:33 PM
Jim Lee
 
Join Date: Feb 2009
Location: Durham, North Carolina
Posts: 61
Head gasket replacement learning process

Hi all, I am in the midst of attempting to replace the head gasket on my 1995 E320 Wagon. It is leaking way too much oil. I just did a Volvo 240 head gasket and got so full of myself I decided to try this and maybe save $1500. I have the only written e320 manual that I am aware of. It is black and blue (appropriate colors) and titled "Mercedes 124 1985-1995" - "Owners Workshop Manual". It is published by Technibooks. Distributed by Motorbooks. It is very English and in the United Kingdom. Anyway this is way different than a Volvo 240. I am trying to follow the directions starting on page 28 for my 6 cylinder 4 valve M104. I think that I have it at TDC which is the first thing they say to do. I have also removed the 4 bolts that attach the exhaust manifold to the pipes. I have removed the rocker cover and ignition wires. What I cannot get is how I am going to remove the head with the intake manifold on as many in the archives have advised. I am definitely going to rent or create an engine lift because there is no way I am going to try to lift that head and intake.
What I am stuck on is how the intake is going to lift detach from the car. I know about the two large pipes that the plastic black intake stuff is attached to and I can easily loosen the pipe clamp on the front one but I am having a real tough time getting to the back one. I don't see how there is enough room to get the phillips head in there and have the amount of leverage needed. Also, I do not see anything in this manual about detaching the fuel line from the fuel rail which I am sure has to be detached before the intake is lifted out with the head. Any hints or tips as to what to do next would be most appreciated. Please look at the three pictures on my website to see if I am at top dead center. I see no indication on either one of the cam wheels that I am but it sure looks like the valves on cylinder 1 are closed.
This is the site with some pictures.
http://home.earthlink.net/~sasjzl/1987volvo240/
If anyone has this same manual can you check that I am looking at the correct information starting at page 28?
Thanks very much,
Jim Lee

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  #2  
Old 02-15-2009, 08:28 PM
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Join Date: Aug 2003
Location: Phoenix
Posts: 3,726
http://mb.auto.pl/wis/w124/CD01/Engine/104/01-4150.pdf

http://www.continentalimports.com/ser_ic100345.html

Also Haynes 124 manual, chapter 2C.
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  #3  
Old 02-15-2009, 09:50 PM
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Posts: 557
screw that, you have to remove the exhaust and intake manifolds completely from the cylinder head, you are going to attempt to pull the head with the exhaust and intake manifold intact? no, that won't work.
really? your serious about this? because that's absolutely not going to work. you gotta completely disengage the every last damn thing on a cylinder head to get it loose and do the job properly. taking the head out with either manifold still attached? no, you can't do that, what are you going to do, take the injection system out with the head....come on....i would stop right now and put whatever you have taken apart back together and think about this.....looks to me as though you not going in the right direction
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Old 02-15-2009, 09:57 PM
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Location: Florida / N.H.
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<>

DISASSEMBLY
The first point of disassembly is to remove the head, intake and exhaust in one unit. So one of the first things we do is to remove the wiring harness from the intake..
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Old 02-15-2009, 10:30 PM
I told you so!
 
Join Date: Jun 2002
Location: Motor City, MI
Posts: 2,853
Jim, I used a winch tied to the rafters to lift off the head from the engine, then slid the car out from under the head. I recommend you go ahead and use something similar, and don't try to manhandle the head off the engine, you'll bang things around too much. The winch will help you control the lift (and installation). I mention this because you were hesitant to use a winch in your MBWorld post.

Pay close attention to the position of the crankshaft and the cam sprockets. Make marks, sketches, and photographs. Make sure the positions of these shafts are in the exact same place when you put things back together.

As you continue with this job, you'll want to search the archives on how to properly remove the timing chan rail guide pin, and how to properly install the timing chain tensioner. Having the head off is also an excellent time to clean the egr tube. Deposits build up where it connects under the throttle body.

Last edited by Kestas; 02-16-2009 at 11:12 AM.
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  #6  
Old 02-16-2009, 07:41 PM
Jim Lee
 
Join Date: Feb 2009
Location: Durham, North Carolina
Posts: 61
Thanks very, very much

Thanks very, very much deanyel. That first link is amazing. It actually looks like a beefed up completion of what this English manual is showing me. Is it from the official CD? I have that but it has been so long and it was such a pain in the neck to look at I probably have lost it.

Thanks again,
Jim Lee





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Originally Posted by deanyel View Post
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  #7  
Old 02-16-2009, 09:37 PM
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Join Date: Nov 2008
Location: Long Island
Posts: 578
If you use a hoist or winch, go SLOWLY. Have a helper with you. Watch carefully for the things that you forgot to disconnect that will break if you pull too hard. Hoses, wires, brackets, cables, etc. Very easy to miss one or two, very easy for the ones you've correctly disconnected to get caught on something. When you lift by hand you can feel the resistance. With a hoist you do not and you can just yank something that doesn't want to be yanked.

Quote:
screw that, you have to remove the exhaust and intake manifolds completely from the cylinder head, you are going to attempt to pull the head with the exhaust and intake manifold intact? no, that won't work.
really? your serious about this? because that's absolutely not going to work. you gotta completely disengage the every last damn thing on a cylinder head to get it loose and do the job properly. taking the head out with either manifold still attached? no, you can't do that, what are you going to do, take the injection system out with the head....come on....i would stop right now and put whatever you have taken apart back together and think about this.....looks to me as though you not going in the right direction
Nah, that's BS. Depends on the engine. I'm not familiar with this particular engine, but often it is much easier to take the head with one or both manifolds and some of the fuel system. When it's on the bench it is much easier to disassemble. The downside is that it is heavier to remove from the car.
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  #8  
Old 02-16-2009, 10:01 PM
I told you so!
 
Join Date: Jun 2002
Location: Motor City, MI
Posts: 2,853
Quote:
Originally Posted by sasjzl View Post
Thanks very, very much deanyel. That first link is amazing. It actually looks like a beefed up completion of what this English manual is showing me. Is it from the official CD? I have that but it has been so long and it was such a pain in the neck to look at I probably have lost it.

Thanks again,
Jim Lee
You can get the same thing - plus lots of other information - online.
http://mb.auto.pl/component/option,com_wrapper/Itemid,62/

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