OM606 Glow Plug Nightmare
 

JUST recently purchased a 1999 E300D with what I thought was 279k miles, turns out the owner didn't know it was kilometers so she's only got about 173k miles. Anywho it had a check engine light for multiple glow plugs being bad. Got the Intake manifold and what do ya know, 4 broken glow plugs and one botched repair job. Attempted to start drilling them out and wasn't straight and now I'm pretty sure the cylinder head is toast. That coupled with the botched repair job from previous owner is say I need a new head. What are my options here? Only paid 2,000 for the car and it's in beautiful shape, and ran great with no leaks at all.....HELP!

If you didn't drill straight you could have likely drilled a coolant passage or oil passage. I hope you didn't aim the drill bit and slip downwards and drill the block.

Most likely you did wreck the head, that's fixable not the block. Heads are not always easy to find, but that may be you're only option.

broken or stuck glow plugs are best removed by machinist not drills. they won't destroy the threads like a drill.

Most likely the other guy didn't heat up the engine properly to remove them. they are a SOB but can't be done with time and patience.

Well fortunately I wasn't off by that much I want to say I was off by about 5 degrees, just drilling out the threads so no deeper than a half inch in. First time I actually could not Accomplish a DIY. I just don't have the ability to get the drill straight enough at the correct angle. I don't suppose anybody has any heads laying around? It seems I could rent most the tools from folks around the forum? Thanks in advance

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Maybe the head can be saved by chasing the threads when the plugs come out or with threaded inserts. Seems you’re in over your head (ha!) at this point so pull the head and take it to a reputable machine shop.

606 heads aren’t easy to find separate from the block or car. Check car-part.com

Curious about the km odometer. Is it a Canadian or Mexican car or an SDS modification?

Sixto
98 E320s sedan and wagon

Well I did a VIN look up and it did get the Canadian package, Speedo is KPH.

I am certainly over my head, but can a good machine shop fix this kind of thing? I'm located in Yuma, not sure if there is a machijne shop in San Diego or Phoenix that could perform the task. I stopped the job after this mistake, but the previous owner looks like he glued in an inser of some sort for one of the other Glow Plugs (this GP came out all cross threaded and mangled)

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Not sure if I have any reputable machine shops in my area, that can work on this head that is. Is it a Mercedes specialist task to machine these out? I'm located in Yuma, AZ, smack between San Diego and Phenoix (2.5 hours either direction) The car itself is in amazing shape and everythijng works perfect, and for the price I feel I can justify any work I have to do. Should I just pull the heads (hard task from what I have read)? The VIN search said Canada Package, as the Speedo is KPH, I assume that's why.

Forget the GPs. Retrofit a Cummins style grid heater in the intake.

How viable of an option is that, I mean the glow plugs will eventually get coked over and effect the burn in the prechamber will they not? Also doesnt help that the one I screwed up broke the seal of the glow plug to the head.

I don't have the same problem but would like to use my om606 twelve month out of the year. I tried a search here and got zero. Any clue to information on the grid heater retrofit. For my, and OPs benefit.

I would think that on the 99 turbo, the Italian tune up could cook off the carbon that you describe when used with the Grid heater, just my guess.

Your head is ok if you only drill 1/2 inch deep , removed the head and send it to kellys machine shop venice ca, he did one for me , but mine wasent drlled call him show them your pictures definetly let the machine shop handle it , they are Mercedes specialist

Is it Kelleys Block Welding in LA? I know there is a place in San Diego, Motor Works Inc. Not sure how reputable they are? I sure hope they can salvage the job, maybe insert a plug into the hole and tap it. Either way, in terms of special tools to pull the head what will I need? Is there a specific chain tool, and a locking pin of some sorts to keep it in time?

Managed to find a head on eBay for $595 with free shipping, but its from Latvia. I would get this head and send it right to the machine shop and have it done up and checked out. Does this seem like an expensive route? I feel like 600 for a used head (200km) isn't too bad

Yes kellys block welding , they do work for our Mercedes dealer for 30 years

Thanks, will I require a chain separator tool or can I accomplish head removal without separating chain

You do not need to separate the timing chain. The sprocket unbolts from the end of the cam shaft. Zip tie the chain to the sprocket in multiple places to preserve the timing. The sprocket is keyed to the cam so it can only go on in the correct position.

Are you sure it’s a turbo head? Are you sure it’s in good shape? Shipping might cost more than the head.

Sixto
98 E320s sedan and wagon

Good News
 

Machine shop, Motor Work Inc. in San Diego, said bring the head down and they may be able to save it, fingers crossed! Now I just have to pull the thing out, time for tons of pictures maybe I'll make a tutorial for others

There are several 606 head removal threads already here, do a forum search. Always room for one more of course, but the existing threads may contain some wisdom that could prove useful for you. I have done it once before, following the FSM to the letter, and it wasn't horrible but it is a lot of hours of work. There are many small rubber parts and other bits that you're want to replace "while you're in there". Also the head is HEAVY so you'll want a friend to help when you get to actually lifting it off, and lifting the repaired head back into place.

Thankfully I got the ol' reliable
 

I do intend to take my time, take lots of pictures forreference, and order things as I go while I'm in there. The machine shop said if they can save the head I can get all the valve guides and seats done, so why not. I did get the Alldata DIY subscription and it seems pretty detailed. Would you recommend getting a 1 day subscription to startek and print, or just use alldata?