yesterday (saturday) i installed my newly rebuilt 240d engine into my not-so-new '77 240D. as usual the project was over budget and over-time, but well worth the efforts in the end; even the installation took longer than expected. long story short, i truly 'finished' installing the engine this morning (superbowl sunday) and cranked her up. i had to reassure myself that turning her over for about 1 minute or so before she kicked in was probably normal for a rebuilt engine that was being run for the first time. anyhow, with the exception of the fuel injector pump being ever so slightly out of time (hardly noticable, though i will have it proffessionally tuned), she runs like clockwork (much better than the previous, low compression engine). there was only one hitch, and this may be minor......we shall see tomorrow. there was a slight oil leak from the cap bolt on the timing chain tensioner. this could be simple in that if i am lucky i can get an offset box end wrench in there to hope fully take it out, re-washer and seal it, then tighten it back down. unlucky if i have to take off the a/c compressor as well as its mounting bracket and the water pump......ugh. wish me luck on fixing the slight leak. any suggestions on how to do this easily would be of great value.
william gum
brand new old '77 240D

Bamboo77,

GREAT JOB!!!!!!

When you started talking about the chain tensioner, I was wondering why this was a big deal. I forgot that on the early models, the A/C compressor is on the right side top. I guess it will be in the way.

If you did not disassemble the tensioner and replace the thin aluminum washer, it may be worth stripping away whatever you have to (maybe you can swing the compressor out of the way without losing the charge) remove the tensioner, seal the gasket surface with silicone and replace the aluminum washer.

You should be able to adjust the injector plenty close enough with the drip method, did you do that?

Best of luck,

larry,
decharging the system is not a problem....it isnt charged anyway the probem is that the bracket which holds the a/c compressor is in the way. this bracket also acts as a bracket for part of the water pump, as well as mounting to the engine mount arm studs. very frustrating. havnt yet tried it, but i think i will be able to get at it by only removing the air cleaner housing and using a 12 sided 22mm box-end wrench. and about the injector, i didnt use the drip method. i set the splines up on the injector, set the crank to 24 deg. BTDC, and installed it at exactly the same angle it was previously in. i was able to do this because when i took it out, i left the bracket bolt on the back of it tight and merely removed the two bolts that go into the case. therefore i was able to return it to its exact angle once more. i'm sure it was out of adjustment to begin with, but i figured this would get me running. i need to get a drip tube.
william

William,
Thanx for sharing your success with us. You have had several posts about diesel guts, so we know you have had this in process. Can you provide a short summary of how it began, the problems you had, and roughly what the costs were? I bet most of us would enjoy this summary!

Great, I too would like to hear any major problems, the cost,and the manuals used..

__________________
2000 Ford 7.3 Powerstroke 4x4
2006 Mazda Tribute
1983 Black 300 D (donated to charity)
1993 Teal 300 D (160K) Sold
"I love the smell of burnt diesel fuel in the morning, it smells like ....VICTORY"

Semper Fidelis
USMC 1973-1976