The idea behind resleeving is one of economics. Pistons are something like 125 ea. while sleeves are something like 25 ea. Thus if the pistons are in good shape (which they likely are) then its much more cost effective to do the sleeves. I pressed my sleeves myself, it wasn't that big of a chore. The shop then bored and decked them. Boring has to happen anyway, so you should save about $400 by sleeving.

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For Sale: 1982 MB 300TD
1995 Chevrolet Suburban 6.5TD

Sold: 1980 IH Scout Traveler- Nissan SD33T Diesel

Those would be awesome photos. I will host high res versions for free for you if you want. The "free sites" often restrict your maximum picture size to kill a lot of the details...
They would be on networkboy.net (not the site in my sig...)
-nB

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'83 300D Turbo
Current: ???K mi - 19.2mpg -> 17.4mpg -> 22.9mpg ---> ODO Died
bought at: 233.8K mi - 10MPG For $1.00
3.5 cylinders work: 320 320 100 340 280
Got insurance? FarmersReallySucks.Com

I second the desire for the photos.
however, I have not had any issues with photobucket.com picture host resizing or limiting the image size.

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

t walgamuth.

Trivial changed to minscule.

P E H

KCM,

gburnett's budget is below the ~ $1000 cost of a new set of pistons.

SO what he is doing is OK as long as the used pistons are not cracked and the ring grooves are OK or rebuilt.

P E H

Have not read ALL the details, but here's how I do it.

Take block to machine shop with new liners and old pistons.
Shop installs liners and cuts each cylinder to each piston minus -0.005thou.

Shop tech' then hones each cylinder to each piston for +0.001"thou clearance.

On TURBO engines I increase clearance to +0.0015" thou.

Never had a engine seize.

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[http://languageandgrammar.com/2008/01/14/youve-got-problems-not-issues/ ]

"A liberal is someone who feels they owe a great debt to their fellow man, which debt he proposes to pay off with your money."

dkveuro,

I think U mean 1 thou or .001 inch.

He hones .006 inch? Thats a lot of honing. He probably bores each sleeve to 0 clearance and hones .001 inch or .0015 inch.

But, Honing is a very slow process and removes very little metal. I would think honing would make the cylinders so smooth, the rings would take a long time to wear in. Usually a slight crosshatch is left on the cylinder walls.

P E H

P E H

My favorite machinist always checks for twist in the block and then if there is enough, he decks the block prior to boring it so that the top is flat and the bores are perpendicular to the top. The head will be milled enough to make it clean and true as well.

The benz blocks generally do not require line boring.

Tom W

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

I appreciate the description and comments that each of you have provided. I am impressed with the breadth of knowledge and experience that I have seen on this forum. I am sure I will make some mistakes along the way as this is the first time I have ventured into this level of engine work.

I took the sleeves, new connecting rod bushings and my collection of pistons and rods to the shop today. With the holidays it is going to be a couple weeks into the new year before they can complete the resleeving, deck the block and true the rods. I will check the piston to cylinder tolerances, ring side gaps, and squareness of piston grooves. I am also working to come up with 5 good identical pistons so I don't have to mix and match size. Even though the diameter difference in the pistons from the two engines I dissassembled is only 0.0028 inch, it sounds like that matters.

The next trip I make to the shop (it is two hours away) I will bring the head to them and they will give me their opinion of what needs to be done on it. There was mention of a leak test to check the condition of the head and valves.

Happy Holidays.

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gburnett

1979 300D 250,000 Miles

You are most probably right. I tell him what I want it and he does it.
And yes, it is ONE THOUSENTHS.

He uses a Sunnen Hone and leaves a plateau finish. The best, he says, for modern ring sets.

I also use Total Seal second rings .

I use second oversize ring sets and file fit so there is only 0.006thou end gap.
This gets the leak down test to under 2% or I pull them again and check for problems.

I use an Assenmacher Leak Down tool attached to the block deck, without the head so I know what the pistons are sealing like.

This takes the head out of the loop.
It usually takes running the piston up and down the new sleeve a few times before it seals well....with some oil of course.
.

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[http://languageandgrammar.com/2008/01/14/youve-got-problems-not-issues/ ]

"A liberal is someone who feels they owe a great debt to their fellow man, which debt he proposes to pay off with your money."

This is not meant to be a slideshow or orderly progression. I simply snapped photos that I thought I might need when I put the pieces back together again. OH NO! Now I remember the Children's tale of Humpty Dumpty. Not many of you are old enough to have heard that one I suspect.

I hope you find something of value here.

Click the link below and it will take you to my area on ImageShack, a free photo hosting service. Under "My Images" click an image to bring up a small thumbnail image, then click on the thumbnail image to bring up the bigger version of that image. After viewing an image a "select all" choice will appear so you can activate all of the thumbnails and move easier through them.

http://profile.imageshack.us/user/gburnett/

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gburnett

1979 300D 250,000 Miles

The photos of the hole in the block & the burned up crank and rod make me sick

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"Any sufficiently advanced technology is indistinguishable from magic"
-Arthur C. Clarke

"I won't be wronged. I won't be insulted. I won't be laid a hand on. I don't do these things to other people. I require the same from them."
--John Wayne.

OBK member#16
77 300D
75 300D (rusty parts car)
73 220D (Dad's)
98 Jeep Grand Cherokee
82 Kawasaki M1

be a good time to update the gloplugs

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1984 123.193 372,xxx miles, room for Seven.

1999 Dodge Durango Cummins 4BTAA 47RE 5k lb 4x4 getting 25+mpgs, room for Seven.

It was not my best day when the connecting rod went through the block.

I am planning for new or refurbished injectors and new pencil syle glow plugs.

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gburnett

1979 300D 250,000 Miles

I wonder how his rebuild worked out. It was a few years ago now.