hey guys, what is the stroke of a 602.960(1991 300d) with 2.5 liter.cant seem to find it on my cd manual.
thanks larry perkins

I'm going to take a guess and suggest that it's 84mm........same as the 603.961.

thanks for the reply.
i have decided to save the throw away 3.5 603.970 by going with the 87mm piston like the 2.5 and the 300d (86-87 603.960)problem is either to buy a large quanity of sleeves that are longer for the 92.4mm stroke of the 3.5(special order) or simply add a extension to the standard sleeve to compensate for the additional stroke of the 3.5.
any ideal appreciated,larry perkins

87mm bore, 84mm stroke, '87 602 turbo.

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Gone to the dark side

- Jeff

Do not add extensions to the exisiting sleeves. You add a seam that the rings will have to cross. Go with the single piece longer sleeves.

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RRGrassi


70's Southern Pacific #5608 Fairmont A-4 MOW car

13 VW JSW 2.0 TDI 193K, Tuned with DPF and EGR Delete.

99 W210 E300 Turbo Diesel, chipped, DPF/Converter Delete. Still needs EGR Delete, 232K

90 Dodge D250 5.9 Cummins/5 speed. 400K

Gone and still missed...1982 w123 300D, 1991 w124 300D

there in lies the problem, rr the sleeves that i need to correctly complete the job dont exist,so a special order to the machine shop is next.
i can get them made for about 27.00 per copy if i order 100,so here is what should happen, every one who has a 3.5 engine that they intend to keep should team up with me and order a set of sleeves. with these sleeves you can take the engine back to 87mm pistons and with the heavy rods i just know this has to be one of the best driving cars i own.
so if you are interested sign up and lets see how many that could be ordered.
also i can arrange for the 2 piece sleeve to not have the joint at a position of a ring,but would rather have the one piece sleeve for ease of machining the sleeve bore.
larry perkins lou ky

Why not try to fix the rods with heat and then re-ring the motor if the cylinder walls are ok and put in a new head gasket and clean up the head a little and once you get it running again, just keep putting in some "snake oil" to keep the oil rings from sticking? It might not work (the re-heated rods), but for my money, I would go that route before I try to out engineer the Mercedes folks and believe problems more severe than a simple bent rod WILL occur when you start putting 2.5 pistons in a 3.5 engine and start using sleeves made to your own specifications that are somehow longer than the sleeves Mercedes used originally. I must admit however, that I really don't fully understand what you are saying you are going to attempt. Anyway, don't let me discourage you, if you can see a light at the end of the tunnel. And good luck.

BenzDiesel

hey, did you give up on your problem or solve it?
larry perkins

Didn't M.B.Doc say a few months back that ALL MB diesels have sleeves? It may not have been as broad a statement as that, but I'm sure it was in reference to a discussion about the 350 engine being so tight that it could not possible have sleeves to which he responded that even the 350 has them.

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1982 300TD 210K miles ("The Replacement" aka "The Anvil") - SOLD
1979 300SD 245K miles (never ending project)
2007 Pinarello F3:13
1995 Ducati 916 (SOLD, sniff)
1999 Ducati 900SSie (SOLD)

I've driven over 3,000 miles now since the work and the car is getting about 700 miles from full to light on, up from less than 200 miles before the work and has gotten better results each time I've had to add the oil. It runs very good, better than it ever has! I'm trying to blow out all of the carbon in it.

BenzDiesel

keep in mind that i am speaking with knowledge up to 1991 on the 3.5 and 1992 on the 300d 2.5, no factory sleeves. will bet you dollat against a donut hole that sleeves on new engines was phased out after the 617 engine.
larry perkins
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