I need to replace 1 or 2 cylinder liners in my 80 240D. I have the engine out and striped down to the crank, the number 2 has a gouge that I believe is too deep to hone out (Looks like maybe one of the rings broke, also a hole in the piston!) and number 3 is just plain loose at the top. Anyone have any tips or tricks for replacing liners? Also looking for the tool. Thanks for any help!!

Yes, you need to access a MB Factory shop manual for this job...
And don't bother thinking about honing out... the cylinders and even new pistons to match them ( said that backwards as you hone each cylinder to fit the piston going into it )... are CHEAP compared to the turbo engines...
The instructions are VERY SPECIFIC in the manual and you need that knowledge to do it correctly.... can't just take it to an American Machine shop and get it right... they are over engineered for long life and reliability... this should be the only time in your life you have to do this to this car....
Are you going to vat the block ? Did you take out the ball bearing sealing the oil passage at the rear of the block ? That should be opened before vatting...

Greg, you gave him some good advice. If he's still around by the time you get done with him you can loan him the tool I made to do this. arpy15, if you're in that far, do it right. Like greg says, knock out the balls, boil out the block. The liners I used need to be precision bored and honed with special rig I certainly don't have. Had a local place do that and boil the block. Cost about $300, half of which was boiling and removing the threaded block plug. You should get it for less (4 cyl), but make sure the shop is very competent with respect to the boring. I pressed and dressed the liners myself with a self-made tool similar to the one shown in the FSM.

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'82 300SD - 361K mi - "Blue"

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