I have two diesels (OM602 & OM617) that have recently decided to begin leaking oil out of the head gaskets. Since I have two wengines to repair, I don't hve the funds to do the job. Thus, I am considering an attempt at a DIY on one. If I do one, why not do both (right?). Are there any online resources to help with this? Also, is this an entirely foolish attempt that will probably require my mechanic to rescue me from myself?

Headgasket not a DIY unless you have an engine lift and access to a machine shop. Valve Cover Gasket super easy and a definate DIY job.

As a paid mechanic myself, there is little I hate more in the world than a second hand/half finished job. If you like your paid mechanic and want him to give you good deals and help you out down the road, do not give him hell by doing this.

I have taken some half jobs in the past and there are customers I've sent doun the road because they made a total cluster-f**k of their "project".

The work is ok. It's finding all the little nuts and bolts that have been taken off and put who knows where. Nothing will get a mechanic red hot like being handed a bag of bolts and then told to put it back together, correctly.

/rant off.

Are you sure it's the head gasket? Where are the leaks on the engines(By the injection pump, back, front, manifolds)? Is it possible for you to post a picture? I'd hate for you to pull the head and later see it was the oil finter housing or something simple like that.

Like rchase said, it's not a DIY job unless you have a few years of serious stuff under your belt. If you drop the timing chain during the process, you will curse at yourself ten times over.

As for online resources, see the Online Mercedes-Benz Service Library link

That certainly can be a DIY job. Not the first I'd tackle though...

Just over a year ago, I replaced the cylinder head, oil pump chain, timing chain, and vacuum pump onan '85 300SD. I did it all in the winter, in my yard, and without a hoist.

No machine shop is needed.

If you are determined, you can do it. Make sure you get a service manual. Haynes, MB, or the CD (eBay).

An make make sure it really does need a head gasket. Are you sure the oil is not from somewhere else?

__________________
Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

I, too, have replaced the cylinder head on the 617.

However, I would not recommend that you attempt this unless you are fairly knowledgeable with engines and especially familiar with the quirks of this engine. There are several critical steps along the way.......which if ignored.......or if screwed up.......will leave you with a pile of hardware that won't run.

It's also very critical to put all the small fasteners in suitable bags and label them as they come off the engine.......otherwise you have no hope of figuring out where they all go.

You need to have a lot of patience for this task. Every step must be planned to avoid costly mistakes.

The procurement of the FSM for the 617 is mandatory for such a task.

I'm 16 years old and did the head gasket on my 250 before having to pull the head again and found a cracked block in which I did an engine swap and put my original head on the "new" engine. I've been working on Mercedes for 7 years so I do know a thing or to but the job is mainly just time consuming and risky if your inexperienced, although no special tools are really required.

The only special tool I needed was for pulling the timing rail on my OM617 which I fabricated out of $5 worth of washers and a bolt. Let me know if you go ahead with the job and I can give you detailed instructions on how to make the rail pin puller.

__________________
Adam Lumsden
(83) 300D
Vice-President of the MBCA International Stars Section