Parts Catalog Accessories Catalog How To Articles Tech Forums
Call Pelican Parts at 888-280-7799
Shopping Cart Cart | Project List | Order Status | Help



Go Back   PeachParts Mercedes-Benz Forum > Mercedes-Benz Tech Information and Support > Diesel Discussion

Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 04-29-2020, 06:32 AM
Father Of Giants's Avatar
Registered User
 
Join Date: Feb 2017
Location: Newport News, Virginia
Posts: 1,597
Decided to repair the 2.5 E300

We where close to scraping it honestly, then my job informed me I will be working in a different location.

Which means my brother can no longer use my car to drive himself to work since I NEED it now.

We have to drill out and re thread intake manifold bolts and repair glow plug wiring.

We put it off because we knew acquiring all the right tools will be expensive

Ended up spending nearly $700 at lowes on a drill, drill bits, wires, wire cutters, electric heat gun, tap and die set and other miscellaneous stuff. I'm honestly just going to drill them all out.

We should start today.

__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.
Reply With Quote
  #2  
Old 04-29-2020, 07:08 AM
oldsinner111's Avatar
lied to for years
 
Join Date: Nov 2008
Location: Elizabethton, TN
Posts: 6,246
why not rebuild it better
__________________
1999 w140, quit voting to old, and to old to fight, a god damned veteran
Reply With Quote
  #3  
Old 04-29-2020, 11:26 AM
Father Of Giants's Avatar
Registered User
 
Join Date: Feb 2017
Location: Newport News, Virginia
Posts: 1,597
I don't know how remove and replace a cylinder head, I also don't have a garage either.

So massive jobs like that won't happen for while.

Also a full rebuild on Mercedes engines is ludicrously expensive.

You could build yourself a fully forged bottom end + aftermarket block V8 for the same price or less.
__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.
Reply With Quote
  #4  
Old 04-29-2020, 11:36 AM
Registered User
 
Join Date: Sep 2007
Location: Calgary Alberta Canada
Posts: 1,924
Quote:
Originally Posted by Father Of Giants View Post

We have to drill out and re thread intake manifold bolts and repair glow plug wiring.

We put it off because we knew acquiring all the right tools will be expensive

Ended up spending nearly $700 at lowes on a drill, drill bits, wires, wire cutters, electric heat gun, tap and die set and other miscellaneous stuff. I'm honestly just going to drill them all out.
With the manifold still on you can't get a straight shot to drill the bolts out. Why not try to twist out the bolts maybe apply heat, penetrating oil, and hitting the bolt with a drift and hammer before trying to twist. The bolts should just twist out.
__________________
92 e300d2.5t
01 e320
05 cdi
85 chev c10
Reply With Quote
  #5  
Old 04-29-2020, 12:05 PM
Diseasel300's Avatar
Registered User
 
Join Date: May 2016
Posts: 6,025
Instead of ruining yet another MB engine, how about using some penetrating oil, some patience, and an external bolt extractor? Drive it down over the head of the allen bolts and they'll either come out or snap off. If you used penetrating oil and waited, they should come right out, they're not that tight to begin with.

Why does the intake manifold even have to come off? If it's that crusty and crappy, leave it. Remove the injector hard lines and go at the glow plug wiring from the sides. You can get in there with a long extension and some patience. Key word: PATIENCE.
Reply With Quote
  #6  
Old 04-29-2020, 12:13 PM
Registered User
 
Join Date: Nov 2010
Location: TX
Posts: 3,978
I 2nd the recommendation of using fluted bolt extractors and some heat along with penetrating oil.
Reply With Quote
  #7  
Old 04-29-2020, 12:28 PM
Father Of Giants's Avatar
Registered User
 
Join Date: Feb 2017
Location: Newport News, Virginia
Posts: 1,597
I drowned seafoam the bolts in seafoam deep creep a day prior and sprayed more on the day of the repair And it still stripped and one broke my tool
__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.
Reply With Quote
  #8  
Old 04-29-2020, 01:14 PM
Diseasel300's Avatar
Registered User
 
Join Date: May 2016
Posts: 6,025
Use a real penetrating oil like Liquid Wrench or Kroil. You're dealing with steel fasteners into an aluminum casting. Lube, time, heat, and percussion will get it out. Use quality tools, don't use round-tip allen bits. Give the bolts a good sharp hit with a hammer 3-5 times before trying to undo them. They will come out. Patience.
Reply With Quote
  #9  
Old 04-29-2020, 01:33 PM
Father Of Giants's Avatar
Registered User
 
Join Date: Feb 2017
Location: Newport News, Virginia
Posts: 1,597
Ok

I'll grab a torch at lowes and another hex key set, and bolt extractor
__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.

Last edited by Father Of Giants; 04-29-2020 at 01:59 PM.
Reply With Quote
  #10  
Old 04-30-2020, 08:45 AM
Father Of Giants's Avatar
Registered User
 
Join Date: Feb 2017
Location: Newport News, Virginia
Posts: 1,597
Was going to start yesterday, but we decided to grab an oxy acetylene torch sometime today.

Some say a propane torch isn't hot enough, I have a lot of reading up to do before I even touch it.
__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.
Reply With Quote
  #11  
Old 04-30-2020, 09:17 AM
Diseasel300's Avatar
Registered User
 
Join Date: May 2016
Posts: 6,025
Acetylene torch? This isn't suspension you're working on, it's intake manifold bolts. Penetrating oil, percussion, quality tools, and patience are all that's required.

Use quality non-ball end socket style Allen bits. After soaking with penetrating oil, clean out the recesses in the heads and make sure the bit is fully seated. Smack it a couple times with a hammer to shock the bolt. Use a U-joint or a spherical swivel joint (my favorite) to get access to the allen bit. Give it a sharp twist to break torque on the bolt. It should then thread out. If you strip a head, hammer the bolt extractor on it, it'll come out.

These things are only torqued to 25nm. They're not that tight. Unless this car was dredged from the Titanic wreck, going full gorilla with a torch is just asking for bigger problems, especially an acetylene torch which will happily melt a hole in your aluminum head, valve cover, intake manifold, or any wiring it encounters.
Reply With Quote
  #12  
Old 04-30-2020, 09:49 AM
Father Of Giants's Avatar
Registered User
 
Join Date: Feb 2017
Location: Newport News, Virginia
Posts: 1,597
Ok I'll back off the acetylene torch, I'll buy a big hammer and punch and start working on it
__________________
1998 Ford Escort ZX2 5 speed - 279,000 miles My Daily

1992 Mercedes 300D 2.5 202,000 - Pure junk
2000 Mercedes E320 Black - 136,000 miles - Needs repair

Don't forget to grease the screw and threads on the spring compressor.
Reply With Quote
  #13  
Old 04-30-2020, 09:53 AM
Registered User
 
Join Date: Dec 2006
Posts: 3,941
These threads are soooo painful to read. Do what Diesel300 says, it's very unlikely that they're not going to come out. And stay away from torches, or we'll be hearing aobut how aluminum melts...who knew?

If the allen hex is really stripped, use a Dremel and grind just the head off. When you remove the intake manifold, the remainder of the screw can be removed with a pipe wrench.
Reply With Quote
  #14  
Old 04-30-2020, 11:33 AM
Registered User
 
Join Date: Sep 2007
Location: Calgary Alberta Canada
Posts: 1,924
Holy yes maybe best to forget about applying heat.
Just how big of a hammer are you going to get?
__________________
92 e300d2.5t
01 e320
05 cdi
85 chev c10

Last edited by dieselbenz1; 04-30-2020 at 02:11 PM.
Reply With Quote
  #15  
Old 04-30-2020, 11:48 AM
Registered User
 
Join Date: Mar 2009
Location: San Diego
Posts: 3,537
$700 is a lot of money to spend on tools to try to remove the intake manifold. I just took out the manifold of an OM603 engine so I know what I am talking. The bolts at the front are easy to remove. Hope you have removed those. This is what I will do.

1) I hope only 2 to 3 are stuck out of the 10 in total.
2) remove the injectors. The hard lines if possible.
3) Use a good allen keys. If you strip the bolt then try to use an extractor or an oversized imperial Allen key, hammer it in. Don't drill as the space is tight.
4) if all failed, cut the bolt head off with reciprocating saw or a saw blade by hand. It is slow but it can be done.
5) remove the manifold and try to remove the studs. You have about 1/4" stud left to grip.

Good luck.

__________________
Not MBZ nor A/C trained professional but a die-hard DIY and green engineer. Use the info at your own peril. Picked up 2 Infractions because of disagreements. NOW reversed.

W124 Keyless remote, PM for details. http://www.peachparts.com/shopforum/mercedes-used-parts-sale-wanted/334620-fs-w124-chasis-keyless-remote-%2450-shipped.html

1 X 2006 CDI
1 x 87 300SDL
1 x 87 300D
1 x 87 300TDT wagon
1 x 83 300D
1 x 84 190D ( 5 sp ) - All R134 converted + keyless entry.
Reply With Quote
Reply

Bookmarks

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On




All times are GMT -4. The time now is 08:46 AM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0
Copyright 2024 Pelican Parts, LLC - Posts may be archived for display on the Peach Parts or Pelican Parts Website -    DMCA Registered Agent Contact Page