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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
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17 Posts
Discussion Starter #1
hi all. I benefited from this site so many times - so it's time to give some thing back...
i just bought w140 (originally 2.8 petrol - now 300d)
the car was converted about 10 years ago by one of the best mercedes indie's in Ireland.
it's w140 with om606.910 non turbo straight 6 engine, automatic

LOVE S-class

so today i went to my friends garage and decided to change the fuel lines(there was air in the system), as i was at it - return lines were changed, fuel filter, oil filter and new oil, new glow plugs, modify intake manifold, belt tensioner and shock, cleaned IM from some of the gunk..... and some more
 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
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17 Posts
Discussion Starter #2
so i said to my self why not take some pics ....

i started by removing a intake manifold

in my car it's held by 2 10mm bolts on drivers side






and on the other side of the engine there's bolt holding vacuum line








i took 2 10mm bolts (red arrows) from the top of fuel filter (it loosened vacuum line so i could take IM off without damaging vacuum). they were holding vacuum line (white arrow) and securing 3 fuel lines from coming out









then i removed 2 10mm bolts holding accelerator cable assembly and one for gearbox cable holding bracket




 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #3
disconnect the accelerator rod from the bracket







now i was able to lift out the long and narrow piece of IM (i don't know the proper name for it)

look out for vacuum line connected to the back of it...



i cleaned the top of the engine with compressed air because i was about to go at intake manifold it self... you don't want anything falling inside ....


undid all bolts holding IM (there's a lot of them)











and lifted IM off - again - watch out for vacuum lines at the back of it

and try not to damage any fuel injector lines as you taking IM off....



my engine looked like that without it




 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #4
since the manifold was off i went at the glow plugs

there's some pics of different types as i was told






and that's the ones i've got(you can't go wrong with originals)







no 1.2 and 3 came out without any problems - but other 3 - REAL PAIN in the .....


that's how they looked.....




 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #5
next - plastic see trough fuel lines




















i was thinking to change only o-rings- but the 4 lines at the dealer came to €45 - so i decided to change lines as well

some difference.......




 

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Cruise Control
'87 300TD/'90 300D/'94 Quattro/'89 Vanagon TDI/'01 EV Weekender VR6
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52,233 Posts
Nice write up. On my 606, I opted to convert all of the o-ring junctions back to the old style with the copper crush washers, since those rarely leak. What is the immobilizer you reference in the glow plug pic?
 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #7
first i did short line on the top of fuel filter

10mm nut (yellow arrow)- remove

nicely lift one end of the line by fuel filter (i used the help of fine flat screwdriver)

other side is held by clip- unclip that one - and pull of the line (red lines is where they go)






BTW - all the lines come with o-rings (difference between o-rings on they own and lines with them was VERY small)


next - fuel strainer


carefully lift strainer of the fuel filter assembly








remove - clean with compressed air ( or with the help of your lungs :) )

there's o-ring to be changed

















next- put strainer back into place it came out of.

i connected far end first (easier to fit last connection where's more space)
 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #8
Nice write up. On my 606, I opted to convert all of the o-ring junctions back to the old style with the copper crush washers, since those rarely leak. What is the immobilizer you reference in the glow plug pic?


thanks a lot Zeitgeist. i've bought other glow plugs few days ago - you can see them in a picture- tread was same and size was very alike - but connection for wires is different. immobilizer ones have to be connected to ecu + IP + glow plugs (safety feature, anti theft)

i have connectors on IP not connected as well - so i assume they were never used because of the conversion - ecu is from w126, engine and gearbox w124, w140 chassis..........
 

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Registered
'95 E300 DIESEL, '91 600SEL, '92 600SEL
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17,408 Posts
Always replace fuel pre-filters and the filter in the fuel tank. Not worth taking a chance re-using such a cheap part when yours is looking so old an dirty.

Please update your profile so we know which vehicle you are referencing. The OM606 was only used on the '95 W124 in the US. The W140 initially had the OM603, but was superseded with the OM606. Only the OM603 was available in the US, which had the dreaded "rodbender" 3.5L turbodiesel.
 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #10
there's line with banjo bolt on the side of IP - connect that first and then fuel filter side.

watch out for small o-ring on the bolt



 

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Cruise Control
'87 300TD/'90 300D/'94 Quattro/'89 Vanagon TDI/'01 EV Weekender VR6
Joined
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52,233 Posts
He mentions that it's a 140 gasser that's been converted over to a 606.10, so it's applicable to folks here with the '95 E300D
 

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Registered
'95 E300 DIESEL, '91 600SEL, '92 600SEL
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17,408 Posts
I would most definitely also replace the main vacuum line running from the vacuum pump to the brake booster.

Yours is being held together with duct tape.:eek::eek::eek:

If that line lets go, you will lose brake assist and won't be able to shut off the engine since your main fuel filter does not have a manual shut off valve. This is a serious safety issue to yourself and to other motorists in addition to preventing a runaway diesel situation.
 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #13
Always replace fuel pre-filters and the filter in the fuel tank. Not worth taking a chance re-using such a cheap part when yours is looking so old an dirty.

Please update your profile so we know which vehicle you are referencing. The OM606 was only used on the '95 W124 in the US. The W140 initially had the OM603, but was superseded with the OM606. Only the OM603 was available in the US, which had the dreaded "rodbender" 3.5L turbodiesel.


thanks for the comment sbaert. i didn't replace pre-filter yet - because dealers didn't have it on time for my DIY.

didn't update my profile yet,

it's w140 1996 - originally s280 - but converted to 300d

engine and gearbox are from w124

om606.910 - is non turbo 24 valve head - one of the best uncomplicated engines ( if not THE best)

it has 265000 miles on the clock - no smoke on start up (after glow plug change), no black smoke on take off or acceleration, so silent- people can't believe it's diesel
 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #15
I would most definitely also replace the main vacuum line running from the vacuum pump to the brake booster.

Yours is being held together with duct tape.:eek::eek::eek:

If that line lets go, you will lose brake assist and won't be able to shut off the engine since your main fuel filter does not have a manual shut off valve. This is a serious safety issue to yourself and to other motorists in addition to preventing a runaway diesel situation.


it's foil to divert some of the heat from metal and rubber connecting parts

thanks for advice sbaert. i'll do that on my next day off next week
 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #16
back to DIY


next - fuel filter - 17mm bolt on the top- unscrew- take the bolt out

there's 2 o-rings to replace






fill NEW fuel filter with diesel or injector cleaner (removes the need of IP doing a lot of pumping ) and put everything together
 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #17
NEXT - belt tensioner and shock replacement


you should be able to do that without taking the fan out

undo the 13mm bolt holding the tension spring, undo 13mm bolt holding tension shock
remove or take down the belt

now is the time for tensioner assembly

17mm (i think hex) - unscrew

keep doing so until bolt is gonna be cumming out of the assembly - easier removal























 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #18
put everything together and reinstall or renew the belt (witch i did)



 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #19
some pictures of old assembly












re bolt new shock and pulley onto new assembly
 

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Premium Member
1996 w140 300d, om606.910 non turbo 24v, 265k mls
Joined
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17 Posts
Discussion Starter #20
since i pulled of the cover off- i decided to check breather pipe and all the lines coming out of it - OMG






















 
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