240D engine resurection, many pictures
 

I've reacquired my old '80 240D. Actually my son bought it from the guy who got it from the charity I donated it to. I've been helping my son rebuild the engine for the last 4 or 5 weeks.

First we removed the old engine.
http://i139.photobucket.com/albums/q...utofthebay.jpg

Then we cleaned up parts as we took them off the old block. We also cleaned up parts from the extra engine we had in the trunk. They were really thick with grime.
http://i139.photobucket.com/albums/q...tscleaning.jpg

you donated euro lights to a charity:eek:.

keep the pics coming:cool:

While my son spent a whole day in the parts washer, I removed parts from the newly extracted engine and also started to build up the block we had machined for first oversize on piston bores and crank bearings.
http://i139.photobucket.com/albums/q...616-wmains.jpg

We had the unfortunate event to notice that the previous owner had ordered the wrong main bearings for this block. The old block had the older style with the thrust washers molded into the third bearing, but we needed the one with the separate thrust washers (bearing).

While taking apart the removed engine, we found most bearings were scored and one was even melted. It's a good thing we had a newly turned and polished crankshaft.
http://i139.photobucket.com/albums/q...edbearings.jpg

Was this engine still running?

Happy Motoring, Mark

What I wouldn't give to have a Safety Kleen out in the garage!
You really ought to have your son wear gloves while working with the parts washer. Very caustic stuff in those.
Will enjoy watching this project come together. Keep the pics coming.....

Thanks. The washer fluid is 99% kerosene. It might have a bit a Gunk in it.

I think it was run out of oil by my friends son. When I took the timing chain out and examined it, I found one section that had two of the links stretched and broken and the remaining one was about to break. My friend thought it would still run, but if it did, it wouldn't have lasted long.

I did, but they were knock-offs.

I put the pistons in while waiting for the correct main bearings. When we got them, the crank apparently didn't have the shoulders widened for 1st oversize thrust washers. So I had to order the standard size.

More waiting...

http://i139.photobucket.com/albums/q...6w-pistons.jpg

Two more shots with more added.

http://i139.photobucket.com/albums/q...efromright.jpg

http://i139.photobucket.com/albums/q...BarenoHead.jpg

Great photos. Haven't seen a 240D block that clean since about January 1975....

Jim

Here's one of the bottom with the oil pump installed. There was all kinds of parts in the basket. It looks like a chain broke previously.

I packed the gears inside the pump with grease. The last time I tried to start an engine from rebuild, the pump wouldn't prime.

http://i139.photobucket.com/albums/q...frombottom.jpg

Getting the chain connected took several steps. First I threaded it over the injection pump gear and on to the crank sprocket. We had to rotate the block on the engine stand to get the chain to the sprocket. Once it was all the way around, we found TDC, put the balancer on and backed it to 24 BTDC so we could install the injection pump.

As for connecting chain to the cam sprocket, we advanced the crank to TDC.

http://i139.photobucket.com/albums/q...16CrankTDC.jpg

The hardest part was getting the camshaft TDC mark lined up. Since we threaded in the chain in a random way, the master link was not at the top whan we were at TDC. It was close, but not quite. So this meant that we had to rotate the engine to TDC and then push the cam out to pop the sprocket off. Then I could reposition the sprocket and reinsert it onto the cam. This took several tries. Here are the results.

http://i139.photobucket.com/albums/q...minglineup.jpg

Nice alignment. Having done a few chain installations on the 190E 2.3-16 engines, a new chain actually surprised me at how precisely the timing marks line up compared to re-using an "old" chain. Jim

Now for crimping the chain.

I bought a crimp tool a number of years ago. I've used it about 6 times so far.

I had to rotate the engine until the master link came up to the top. I used the tool then to crimp the ends over on the side of the link. Here are two pictures of the crimp in process.
http://i139.photobucket.com/albums/q...ncrimping1.jpg

http://i139.photobucket.com/albums/q...ncrimping2.jpg

And here is the result...

http://i139.photobucket.com/albums/q...aincrimped.jpg