Since I am totally screwed on removing the sheared off glow plugs, and drilling out did not work. I now have to pull the head.

Upon removing the valve cover, and taking a long look at the timing chain, I have come to the realization, that before I fool with the timing chain, I need to find the neutral position for the cam. Anyone have any ideas where zero is at or should I say the safe position to undo the timing chain.

Any other wisdom, before I screw myself any worse than I already have so far, please pass it along.

Thanks,

I would not attempt to remove the head on any M/B without the factory service manual in my possession.

There are specific steps required to support the timing chain so you don't lose it off the crankshaft and there are specific steps required to remove the camshaft so you don't break it.

And, yes, you can screw yourself much worse than you have already if you attempt this procedure without the FSM.

I agree, I wouldn't attempt the job without the manuals.
My MB-WIS has extremely detailed instructions on how to remove the '99s head....I've looked them up because I'll be changing my glowplugs this week too--and they're all original at 158k(!)

I think there are some special tools required that are also listed in the manual. Correct me if I'm wrong, I believe the engine position for head removal is Cyl 1 TDC?

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99 E300 TD -- sold
01 540i 6 spd

This is one of my fears in the life of this 606.962. Dealer put new ones in a couple years ago, so this is on the current to do list.

Seems like aklim had his off at some point after his was stuck, he may chime in later or you can sift through his posts. Seems like he did it but I do not recall specifically.

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raMBow

1999 E300DT Obsydian Black Metallic, Heated Full Leather Parchment options, E2, K2, 136,000+, best 36.5 mpg - GP's 12-04 & 11-12 Zero Stuck
2010 Honda Odyssey - The BrideMobile - best 26.5
(2) 2005 Honday Accord- (1 -Corporate 1 - Personal) - 110,000 4-cyl 30mpg
2000 VW Golf GLS TDI, Upsolute Chip (sold to Brother, now 300+k on it) 48.5 mpg like clock work
1987 Honda CRX HF - Sold 87,000 always over 50 mpg Max 67 mpg

Aklim did not do it. Aklim had it done. The best person would be 210OELmotor who is my MB tech and Gilly who had something to do with the head removal. Other than that, I might be able to find it in WIS as to the head removal instructions.

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01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
03 SeaDoo GTX SC Yellow
04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow

Thanks as always for yall's wisdom and advice. Any ideas where one can download or find to read the MB-WIS service manual that several of you have referenced. I will also try the Autozone DIY site that scott referenced as well.

I will admit that I am new to wrenching on Mercedes, and really have zero knowledge of how the come apart and go together. I did however stay at a Holiday Inn last night, so I think that may push me over the top.LOL But racing over the years has made me a damn good mechanic on a lot of different motors. We have stuck pistons and blown up motors only to tear them completely apart, and put new pistons back in, completely reassembled the entire motor, and put it back in the race cars all in a couple of hours to compete in races. I always thought driving race cars was about driving, and let me tell you it is more about being a good mechanic. So I am hopeful that I have attained the skill set to not completely screw the pooch a second time on this.

I will say this, looking at the top of the valves last night, this motor does look perty, and build like a brick sheet house for those who have never open Pandora's box up.

Please keep the wisdom coming. Thanks,

Here is a link to AllDataDIY's cylinder head removal/installation instructions for their sample vehicle page. The instructions for the 606 does not have the assembly drawings, but all the similiar steps and figures are there.

'95 AllDataDIY Totoya DOHC Cylinder head removal/installation sample

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Scott C.

2006 E320 CDI (120k miles)
FOR SALE: 1998 E300 Turbo Diesel - Black w/Tan Leather - Euro delivery (236k miles)

I've found that Autozone's AllDataDIY site has surprisingly detailed instructions and diagrams for removal & installation of the cylinder head along with torque specs. and related MB technical bulletins.

I am thinking of skipping the 'glow plugs only' on mine and just plan on pulling the head sometime this summer. I'd be interested in hearing your progress. Good luck!

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Scott C.

2006 E320 CDI (120k miles)
FOR SALE: 1998 E300 Turbo Diesel - Black w/Tan Leather - Euro delivery (236k miles)

Is this a v6 or inline engine?

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Jim

Inline six, 3.0 liters, DOHC 24 valves turbo.
606 is basically a 603 block and a 24-valve head.

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99 E300 TD -- sold
01 540i 6 spd

Inline

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raMBow

1999 E300DT Obsydian Black Metallic, Heated Full Leather Parchment options, E2, K2, 136,000+, best 36.5 mpg - GP's 12-04 & 11-12 Zero Stuck
2010 Honda Odyssey - The BrideMobile - best 26.5
(2) 2005 Honday Accord- (1 -Corporate 1 - Personal) - 110,000 4-cyl 30mpg
2000 VW Golf GLS TDI, Upsolute Chip (sold to Brother, now 300+k on it) 48.5 mpg like clock work
1987 Honda CRX HF - Sold 87,000 always over 50 mpg Max 67 mpg

Heck, there is nothing to it if it is an inline 6.
Put the engine at TDC and lock the flywheel in place. Mark the chain in relation to the cam sprocket and just re-install in the same position. Should be pretty straight forward.

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Jim

Does the 603 have the similar head design as the 617? I think what causes a person so much fear when looking real close at the head, contemplating removing the thing is that there is this lack of ability to get to the bottom sprocket. It is housed in what many here on this forum seem to call the "abyss." My 617 is stripped down to rockers, and I'm going in for the job, but I got to tell you, the abyss scares the crap outta me. A slight indescretion and a weekend job turns into an engine rebuild.

???

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-justin

1987 300TD, 1987 300TD
2008 R32, 2000 Passat Wagon

nhdoc, thanks for the write up, that is awesome. Where does one buy that $15 subscription, that sounds like monies well spent.