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-   -   China engine replacement 1980 240D (http://www.peachparts.com/shopforum/diesel-discussion/194431-china-engine-replacement-1980-240d.html)

JimmyL 07-20-2007 02:22 AM

Well, this was a fairly productive day!! I got the engine pulled out of China, and got the other engine installed and even got it stabbed by the tranny and secured! Wow, all this by myself. It would HAVE to be so much easier with help, but it is doable alone. But there is a ton or work left to do before I ever try to spin the starter. {hmmm, now where did I put that starter??}

Had to protect that condenser

http://i29.photobucket.com/albums/c2...D/China043.jpg

engine moves towards said condenser, and engine just clears tranny ans shaft

http://i29.photobucket.com/albums/c2...D/China044.jpg

http://i29.photobucket.com/albums/c2...D/China049.jpg

Also have to secure the oil cooler out of the way. Easier when both lines go to the bottom, as opposed to top/bottom configuration.

http://i29.photobucket.com/albums/c2...D/China046.jpg

Getting ready for the yank

http://i29.photobucket.com/albums/c2...D/China045.jpg

gaining altitude....

http://i29.photobucket.com/albums/c2...D/China050.jpg

JimmyL 07-20-2007 02:23 AM

Due to a lip at the entrance to my garage, I have to lift the engine and pull the car out from under it. I'm not sure what happened to my high altitude engine pic. It was UP THERE! My best diesel pulled China out from under the locked up engine

http://i29.photobucket.com/albums/c2...D/China057.jpg

I had to sit the engine down on the concrete and prepare to remove the clutch, pressure plate and flywheel for installation on the "new" engine.

http://i29.photobucket.com/albums/c2...D/China055.jpg

http://i29.photobucket.com/albums/c2...D/China061.jpg

clutch and pressure plate removed

http://i29.photobucket.com/albums/c2...D/China062.jpg

Heavy arse flywheel removed

http://i29.photobucket.com/albums/c2...D/China064.jpg

This is what is waiting for new engine/flywheel/clutch/pressure plate....

http://i29.photobucket.com/albums/c2...D/China051.jpg

http://i29.photobucket.com/albums/c2...D/China052.jpg

You can see the piston from the slave, shiny shaft, left of pic

http://i29.photobucket.com/albums/c2...D/China053.jpg

I had pulled clutch fork out some for viewing.

JimmyL 07-20-2007 02:24 AM

Here is the AC compressor and hoses secured out of the way, mostly, ready for the "new old GERMAN" engine.

http://i29.photobucket.com/albums/c2...D/China059.jpg

Keeping the hoses out of the way and moved around proved to be quite a task.

http://i29.photobucket.com/albums/c2...D/China060.jpg

With clutch stuff back in, oil filter housing bolts tightened {which were amazingly loose} and new thermostat in place, it was time to try and install the engine. This was my 3rd engine to pull, but my first one to install. Sure is easier just to yank them out......

http://i29.photobucket.com/albums/c2...D/China065.jpg

a little altitude. After I had the engine up like that I had to push China back under it. Luckily I was able to push from the door, rock it a bit, push some more, then dive on the emergency brake before it rolled back. Had to look stupid were somebody watching....

http://i29.photobucket.com/albums/c2...D/China066.jpg

http://i29.photobucket.com/albums/c2...D/China067.jpg

Oh, and I did install new engine mounts, and of course I cleaned the upper covers that go over them....

Here is pick of engine tranny mated and tightened down.

http://i29.photobucket.com/albums/c2...D/China068.jpg

It was interesting trying to line everything back up, level it correctly, move the hoist little bits with large pole for leverage {wheels don't turn on the hoist very good}, then get the bolts started and tightened down.

The hard part will be hooking everything back up, and figuring out the accelerator linkage differences, vacuum line differences, etc.....

Now, where the heck is that starter.........:eek:

http://i29.photobucket.com/albums/c2...D/China069.jpg

2.5Turbo 07-20-2007 02:33 AM

Quote:

Originally Posted by lietuviai (Post 1566617)
I thought this thread was about replacement engines from China.:eek:
Phew! I'm glad it's not. I could imagine a POS engine from China with injectors from India.:rolleyes:

That's what I thought too! I had images in my mind of a turbocharged 616 clone like the Indian ones...

Rashakor 07-21-2007 05:46 PM

like Whiskeydan,

I am pissed you did not invite us to lend you a hand.
come on Jimmy next time do a roll call!!!

JimmyL 07-24-2007 02:19 AM

These freakin Mosquitoes have made it where I don't even want to go outside in the evenings after work. Even covered with bug spray, they still are bumping into your face, and looking for any one spot without the spray. They are biting through clothes this year. Man.........

I have done a few other things. First, looky what I found...

http://i29.photobucket.com/albums/c2...D/China071.jpg

I got the AC compressor and lines hooked back up. It definitely is doable as far as keeping the AC system intact during an engine change. Adds a few slowdowns during the swap, but not that bad.

http://i29.photobucket.com/albums/c2...D/China074.jpg

http://i29.photobucket.com/albums/c2...D/China075.jpg

This sure is an ugly little engine compared to the seized one I removed. Well, I guess that is better than, uh, seized!

And this brings me to the latest hiccup. I never knew this, until now, but there are at least 2 different styles of power steering pulley. One, the old one, is just a straight pulley on the shaft of the pump. Well, the other style is offset, for lack of a better term right now. But the pulley is semi bell shaped, so the groove of the pulley rides farther back towards the pump, lining up with the crank pulley. You can kinda see from this pic.

http://i29.photobucket.com/albums/c2...D/China073.jpg


Here, you can kinda see how this pulley is very straight.

http://i29.photobucket.com/albums/c2...D/China070.jpg

Now see how this one is offset

http://i29.photobucket.com/albums/c2...D/China076.jpg

http://i29.photobucket.com/albums/c2...D/China077.jpg

So it looks like I am going to have to swap power steering pumps. Why the pumps, and not just the pulleys??? Well, first I had a very hard time getting the nuts loose on the shaft. Probably from years of turning the engine with the power steering nut. They were very tight, and it takes 2 wrenches. One for the nut, one for a collar thing that keeps the shaft from rotating. **Uhm, note to self: When pulling the very long 3/4 cheater bar towards you with all your might, make sure it is NOT going to slam into your head** :dizzy2: Darn near knocked myself out! :eek:

Well, I got both of the power steering nuts removed, but neither one of those pulleys are going anywhere. Prying was comical. Tried to use a puller, but the outer edge of the pulley bends/deforms well before the pulley comes loose.
So, next I will be swapping the whole pump. Not that hard at all, just will end up being messy.
I hate messy!! :musicbooh:

Hit Man X 07-24-2007 06:57 AM

I lost quite a bit of blood tonight too due to the bugs. :mad: Got the 300SEL ready for the brackets to be reinstalled, attempted (and failed) to adjust the Solex on the 280S, did a trunk seal on the 300SD, claybar/polish/wax the 240D, and started to remove everything to jerk and tear down the motor. :eek::D

Whiskeydan 07-24-2007 11:05 AM

Jimmy, Can't you find a big fan laying around there to keep them mosquitos at bay? :D

JimmyL 07-24-2007 11:17 AM

Quote:

Originally Posted by Whiskeydan (Post 1571689)
Jimmy, Can't you find a big fan laying around there to keep them mosquitos at bay? :D

I think these things are genetically engineered! Carbon-fiber wings and titanium snout! :overlord:

rrgrassi 07-24-2007 11:41 AM

Good job! Can't wait to hear China fire up!

chasinthesun 07-24-2007 12:25 PM

Jimmy ,did you get my message on those seats ,just like your yellow car ,in very good shape ,look at your message center.

JimmyL 07-24-2007 12:33 PM

Quote:

Originally Posted by chasinthesun (Post 1571764)
Jimmy ,did you get my message on those seats ,just like your yellow car ,in very good shape ,look at your message center.

Yes, and I sent you a reply back. Did you not recieve that? I'll check my "sent" stuff....... **edit** you sent via email. Check your email Dave. :D
I know somebody else who needs some Henna interior stuff also. {Mustang Man298}

SwampYankee 07-24-2007 02:48 PM

Jimmy, great pictorial and account of your swap! When I finally do one I'm hoping that it will be out of convenience and desire rather than necessity.

JimmyL 07-25-2007 12:47 AM

Quote:

Originally Posted by JimmyL (Post 1571499)
Well, I got both of the power steering nuts removed, but neither one of those pulleys are going anywhere. Prying was comical. Tried to use a puller, but the outer edge of the pulley bends/deforms well before the pulley comes loose.
So, next I will be swapping the whole pump. Not that hard at all, just will end up being messy.
I hate messy!! :musicbooh:


Wrong!! No pump swap necessary. I just wasn't using the correct tool. That's right, a Hammer!!! What was I thinking? I just whammed the pulley from the back and spun and whacked....... Off it came on the bench.
Then the one in the car was a little more stubborn, but it finally blasted off the shaft, bounced off the back of the headlight, and came to rest below. Put some anti-seize on the "new" pulley and on it went. Did belt at the same time, loosened pump brackets, slid belt on pulley, then slid pulley on shaft and woodruff key.
Making progress slowly, but, making progress......:)

Whiskeydan 07-25-2007 11:24 AM

Keep that hammer handy so you can remove the 'pulley wobble' later. :D


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