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  #1  
Old 10-21-2008, 07:46 AM
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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.


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.


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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #2  
Old 10-21-2008, 07:51 AM
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you donated euro lights to a charity.

keep the pics coming
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81 Mercedes 300SD 289k.......SOLD
82 Mercedes 300CD 252k......slow ride

82 mercedes 300 SD...mi Unknown
83 Mercedes 300D ????ksniff..gone too
84 Mercedes 300D 148k........SOLD
85 Mercedes 300TD 386k and holding some one elses project
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  #3  
Old 10-21-2008, 07:52 AM
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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.


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.
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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #4  
Old 10-21-2008, 10:19 AM
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Quote:
Originally Posted by mplafleur View Post
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.


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.
Was this engine still running?

Happy Motoring, Mark
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  #5  
Old 10-21-2008, 10:38 AM
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Location: Sunnyvale, Texas (DFW)
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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.....
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Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John
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  #6  
Old 10-21-2008, 11:11 AM
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Quote:
Originally Posted by JimmyL View Post
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.
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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #7  
Old 10-21-2008, 11:17 AM
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Quote:
Originally Posted by Mark DiSilvestro View Post
Was this engine still running?

Happy Motoring, Mark
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.
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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #8  
Old 10-21-2008, 11:19 AM
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Quote:
Originally Posted by JackG View Post
you donated euro lights to a charity.

keep the pics coming
I did, but they were knock-offs.
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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #9  
Old 10-21-2008, 11:33 AM
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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...

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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #10  
Old 10-21-2008, 06:42 PM
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Two more shots with more added.



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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #11  
Old 10-21-2008, 07:28 PM
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Location: Woolwich, Maine
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Great photos. Haven't seen a 240D block that clean since about January 1975....

Jim
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Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)
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  #12  
Old 10-21-2008, 11:13 PM
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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.

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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)


Last edited by mplafleur; 10-21-2008 at 11:19 PM.
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  #13  
Old 10-22-2008, 12:13 AM
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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.



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.

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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #14  
Old 10-22-2008, 01:57 AM
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Location: Woolwich, Maine
Posts: 3,598
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
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Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)
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  #15  
Old 10-22-2008, 12:59 PM
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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.




And here is the result...


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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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