The 6-sided hex bolts are stuck tight as bejeezus. The 12-points are no problem at all. Looks like I may have to drill them out and remove the bolt shafts after head removal. Has this happened to anyone else? Everything else came off with no problem.

I'd try to apply some penetrant and then a lot of torque. Drilling the bolt heads off sounds too much like work. Even breaking the bolt head off (which I doubt) is less work than drilling them. They are pretty hard.

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'82 300SD - 361K mi - "Blue"

"Good judgement comes from experience. Experience comes from bad judgement."

listen, look, .........and duck.

You are using a three foot power bar? Have had them release with a sudden snap on some engines. (not mercedes) . Never got to the point of considering if a pipe should be added to the power bar or perhaps a good impact tool might be better. They should come. If you eventually get them out check the threads very carefully and measure them to see if they have been seriously stretched before reusing them. I do not like the ideal of taking the heads off the bolts on the chance the threads have rusted in the block. not much of a possibility but.

Liquid Wrench worked real well when i had to remove a caliper....worked so well all i used was a 1/2" drive socket wrench...no breaker bar / power bar.

PB Blaster im told is also good.

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82 300SD 145k
89 420SEL 210k
89 560SEL 118k
90 300SE 262k RIP 5/25/2010
90 560SEL 154k
91 300D 2.5 Turbo. 241k
93 190E 3.0 235k
93 300E 195k

giver hell! and if that doesnt work use a longer pipe!

they wont break. use a six point socket and make sure it is on fully and you are pulling absolutely square.

tom w

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

Got the head off finally- #4 piston has a small square notch in it facing the rear-about 1/8" wide-as well as some scratch/scuff marks on the top of the piston, so it's not shattered anyway. Bad valve adjustment? Valves look ok at first glance and there is some oily residue on the block at that piston that may indicate a bad cylinder head gasket there. I'll take some pics this weekend.

how the valves could do that. maybe a part of a glow plug broke off sometime. or a part of a valve or such. any thing hard would do it. pistons are meant to compress air not steel.

also if the gasket leaked enough and it sat and the liquid built up in the cylinder, when starting was attempted it could have broken the piston. i wouldnt be surprised if the "notch" goes on down the side of the piston.

ether could have done it too, i imagine.

bad luck. now you will have to have the engine out to get that piston out.

sorry.

tom w

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.