I recently had the head off of my 606 engine. After reassembly, here are the issues:
1. Difficult to start
2. Once started, engine runs very poorly. will struggle to stay alive when cold, but when begins to warm up, if I don't keep foot slightly on pedal it will just die.
3. When idling, it smokes like crazy.
4. The second I drop it into gear, engine dies. Even if I try to keep a little pressure on accelerator.

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Mike Mass
Freehold, NJ

1999 E300 TD 178,000 miles
2007 E320 Bluetec - Sold

1998 E300 TD - R.I.P.

Have you checked for air leaking into the fuel supply lines?

Nice to rule out the basics first...

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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)

fuel filters

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1985 300TD Turbo Euro-wagon
1979 280CE 225,200 miles
1985 300D Turbo 264,000 miles
1976 240D 190,000 miles
1979 300TD 220,000

GONE but not forgotten
1976 300D 195,300 miles
1983 300D Turbo 175,000 miles

http://i42.photobucket.com/albums/e3...e485-1-2-1.jpg

brand new fuel filter installed. hasn't even been driven on yet. And we bled the hell out of the fuel lines when putting everything back together. I'm pretty sure we got all the air out. I don't see any bubbles.

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Mike Mass
Freehold, NJ

1999 E300 TD 178,000 miles
2007 E320 Bluetec - Sold

1998 E300 TD - R.I.P.

Well timing issues kind of boil to the surface. I would check them all out. Make sure the camshaft is on the right cycle. You would not be the first. Why was the head pulled?

My car ran like that when I got the fuel lines crossed. Make sure they're all in the right order. The two that go to the lift pump fit VERY well backward...

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-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

First off, thank you all for responding. I really need this forum for mechanical help and it has proved successful in the past with all your help.
I very well suspect the timing as well but if it somehow slipped, I wouldn't know where to begin. That being said, we were very careful to keeps things aligned. The reason for the head coming off is a very long story. Simply 2 GP's broke off and all extraction methods failed. I've been out of commission for over 3 months now.

KarTek, Good suggestion on the fuels lines crossed. We'll check that tomorrow. If I do have a timing issue, where do I start?

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Mike Mass
Freehold, NJ

1999 E300 TD 178,000 miles
2007 E320 Bluetec - Sold

1998 E300 TD - R.I.P.

Here's a picture of the fuel system:

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

that exploded diagram of the fuel lines is really helpful. Thanks Evan. I'll report back tomorrow.

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Mike Mass
Freehold, NJ

1999 E300 TD 178,000 miles
2007 E320 Bluetec - Sold

1998 E300 TD - R.I.P.

Fuel Lines all in proper place. No air bubbles running through fuel lines. No leaks. I'm thinking the timing, but everything looks lined up perfectly. Any other thoughts?

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Mike Mass
Freehold, NJ

1999 E300 TD 178,000 miles
2007 E320 Bluetec - Sold

1998 E300 TD - R.I.P.

You are absolutely certain the lower ends of #83 & #74 aren't reversed where they enter the lift pump?

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

Yup, Certain. By the way, terry. You were going to send me a pdf file referencing the timing marks about a month ago. Never got it. I think I've seen the same information else where. Either way, I'm 99% sure we got the timing set correctly, so still trying to figure this out. I had absolutely no issues with the way the engine ran prior to head coming off.

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Mike Mass
Freehold, NJ

1999 E300 TD 178,000 miles
2007 E320 Bluetec - Sold

1998 E300 TD - R.I.P.

I believe you didn't email me your email address using the email link here? Do so, and I'll send you what I have.

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

I have just gone thru the same deal, sans the GP breaking, condolences. My DV's were leaking and when replacing the seals, I did not like the looks of the fuel lines. Hard & brittle, so I replaced all.
This cured the hard starting, stalling at idle, etc.
If those fuel hoses are original, I would spring for new. After changing, I did a diesel purge and I am back to nearly new acceleration, with improved mileage.

Good Luck

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Gary
Experience is something you get, Just after you needed it....
'99 E300 295K, '83 300D 220K, '75 240D 185K sold
'80 MCI Bus Conv DD 6V92TA, w/4 cyl. Kubota diesel GenSet 12.5KW

I'm assuming the smoke is white and theres LOTS of it? If so - that's a classic sign of retarded timing...or you have tractor pulling fuel system parts installed.

This happened to me with my old '98.4 Dodge/Cummins with the P7100. I had it all apart to replace the gearcase gasket (requires pulling IP, camshaft, etc.) and while I was at it - I got the timing wrong...very, very wrong. It wouldn't start/idle worth a darn and the smoke was insane. Properly set timing and no other changes - and it was fine.

I'd appreciate it if you could send me any PDF files as well. I'm pretty sure my email address is listed in my profile. Including it here would be an open invite for SPAM. I'm trying to acquire all the info I can get my grubby hands on for the OM606.962...

By the way - what is #155 on that diagram?

Cheers,

Matt

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'99 W210/OM606.962 - bone stock for now.
'94 Dodge/Cummins - NV5600, P7100, ~400hp
'96 Jeep ZJ - Cummins ISB 170/Allison LCT-1000 conversion project basket case
'00 VW Jedi - 345k, bone stock