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Old 01-25-2008, 03:18 PM
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Parrot of Doom Parrot of Doom is offline
1997 W210 E300TD 243,000
 
Join Date: Mar 2006
Location: Manchester, UK
Posts: 983
Repeat the above steps for the 5 remaining valves.

6) Putting things back together

Once the valves have all been screwed in by hand, get the torque wrench out and torque each valve up to 26 ft/lb (35 nm). Slide the collars back over the spines (taking care to observe the order they were removed), and screw the collars back down with the 3 screws. You should be looking at this:



Screw each injector line back onto the valves, starting with line 1 working through to line 6. No torque figure for these, just tighten them up, then an eighth/quarter turn more, and that should be that. Then screw each line back onto it's injector, observing the same degree of tightness:



Take care that the fuel lines are correctly aligned - there are plastic clips to guide them. Watch that no plastic fuel lines get in the way.

Reinstall the intake manifold - this is a pig of a job and you'll need 4 hands to do it. Theres no way to describe it, just put it back together (refer to the EGR thread if you like). Use gasket paste to ensure a better seal between the manifold and the head (we reused the existing gasket, its metal and still a good seal)

You can of course clean the oily crud from the intake manifold if you like, and the EGR as well. You'll need a bottle brush and some degreaser for that.

7) Crank like crazy

This is where your battery gets tested. There will be loads of air in the system now, and you're going to have to crank for a good 2-3 minutes (crank no more than 10 seconds a time, with 20 seconds inbetween).

My battery gave up the ghost here, so I nipped down the local autofactors and bought a new one. Well its had a good 5 years anyway, and was getting a bit tired. Plus I got it at trade price, so it only cost me £50

Eventually the engine should fire back to life, it will stumble a bit but once the air has been pushed out the system it will be fine. Leave it running for 5 minutes to restore some charge to the battery.


I did have a heart in mouth moment on the way home, a massive THUNK from under the bonnet - fortunately it was the pipe from the turbo popping out of the EGR valve under the manifold. Either not inserted fully, or a clamp has broken, either way at least it wasn't the fuel pump exploding

Bigger pictures here:

http://www.flickr.com/photos/soundman/sets/72157603792018546/

Heres a picture of the reason why they were all leaking:



And here's a very square (should be round) cross sectioned o-ring:



Hope this all helps!
Attached Thumbnails
OM606 engine (W210 E300D/TD) delivery valve seals-2218545695_43a2d39144_b.jpg   OM606 engine (W210 E300D/TD) delivery valve seals-2218545965_712872fb30_b.jpg   OM606 engine (W210 E300D/TD) delivery valve seals-2219339274_100fe32bf8_b.jpg   OM606 engine (W210 E300D/TD) delivery valve seals-2219340976_fb279950c3.jpg  

Last edited by whunter; 12-13-2010 at 05:08 AM. Reason: attached pictures
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