Just finished up replacing the block heater. Not as bad as originally thought! Ended up using 35mm socket with 5' cheater bar and she came right out! While I was at it, the evil green coolant had to go, replaced the turbo, polished the valve cover and intake manifold, and adjusted the valves.

The photos show the stripped block w/new block heater, the old turbo, things going back together, and the finished product. (and yes the evil green coolant)

Overall a smooth project, no frozen bolts ect. Note the '79 manifold (NO egr )

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1983 Mercedes 300SD
1987 Mercedes 300SDL
2001 VW Passat 2.8 AWD
2007 OM642 Jeep WK 4x4

Thats pretty freakin sweet.

I like that much better, I used lots of engine acid to clean mine up, its got the clean bone dry look, but the polished is much better, what exactly did you use?

Also, did your rebuild your turbo or put a new/used one on? Mine is coming off soon for a rebuild or replace.

I also plan to install a block heater, mine never had one. I could have sworn it was a 46 mm socket? I recently just bought one!

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1980 500SE/AMG Euro
1981 500SEL Euro
1982 380SEL
1983 300TD
1983 500SEC/AMG Euro
1984 500SEC
1984 300TD Euro
1986 190E 2.3-16
1986 190E 2.3
1987 300D
1997 C36 AMG
2003 C320T 4matic

past: 1969 280SE 4.5 | 1978 240D | 1978 300D | 1981 300SD | 1981 300SD | 1982 300CD | 1983 300CD | 1983 300SD | 1983 380SEC | 1984 300D | 1984 300D | 1984 300TD | 1984 500SEL | 1984 300SD | 1985 300D | 1986 300E | 1986 560SEL | 1986 560SEL/Carat | 1987 560SEC | 1991 300D 2.5 | 2006 R350

Well, for the polish I just used an abrasive compound and .. well polished the metal. The valve cover is not as reflective as I would like it to be, but while polishing it I noticed many defects that made the venture not worth the time so I did not finish with the full buff. I will keep my eye out for a good example and polish that to my liking. I sure wish I hadn’t thrown all those spares away; I had quite a few lining my shelves before I cleaned my shop out.
The turbo was used but very tight. It was replacing one with 325K of service and I think it will do just fine!
For your block heater, if you have never had one you will need a rather large allen wrench socket to remove the allen plug. I already had a block heater, but the old one was defective. The heater comes in two parts. A outer conversion ring and the heater itself. The outer ring must be the forty-six mm you are speaking of, but the heater itself was thirty-five. The outer ring is almost twenty pounds tighter than the heater so you can just do as I did when the element burns out. I think it was fifty-six foot pounds for the heater, and seventy something for the ring. In any case the kit comes with detailed instructions.
Have fun! I have attached a photo of what happens when you slip off the wrench while trying to get that thing out.... (and that was THROUGH GLOVES!)

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1983 Mercedes 300SD
1987 Mercedes 300SDL
2001 VW Passat 2.8 AWD
2007 OM642 Jeep WK 4x4

I did one awhile back on a 240D that never had a block heater. I think it was a 19mm allen, but it took an air hammer to loosen the plug and three guys pulling on an 6ft bar to bust it loose (pulling from under the car on a lift). Not a fun day! Thats why I'm kind of reluctant to do it on mine. There also the chance I might crack my block...

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1980 500SE/AMG Euro
1981 500SEL Euro
1982 380SEL
1983 300TD
1983 500SEC/AMG Euro
1984 500SEC
1984 300TD Euro
1986 190E 2.3-16
1986 190E 2.3
1987 300D
1997 C36 AMG
2003 C320T 4matic

past: 1969 280SE 4.5 | 1978 240D | 1978 300D | 1981 300SD | 1981 300SD | 1982 300CD | 1983 300CD | 1983 300SD | 1983 380SEC | 1984 300D | 1984 300D | 1984 300TD | 1984 500SEL | 1984 300SD | 1985 300D | 1986 300E | 1986 560SEL | 1986 560SEL/Carat | 1987 560SEC | 1991 300D 2.5 | 2006 R350