616 rebuild options - Page 2 - PeachParts Mercedes-Benz Forum

subetealabici · #16 08-19-2011, 02:31 AM

Well I got around reading the manual a bit, mainly the part about the cylinders, I use the screw again to push the sleeves in, I started with a rubber mallet and a hammer and a wood block for the first 4cm, to be sure that the sleeves were going straight I use just a caliper.
Once the sleeves were centered and about 4cm inside then I used the screw, It was interesting how the sleeves advanced in the block, it wasn't in a linear way it was more by little steps like I imagine the screw stretch until the sleeve give up and advance like 2mm or 3mm each time almost like a spring loaded mechanism, I used also a wood block and then a nylon block to smoothen the axion.
Well the third sleeve worn me out, I may finish tomorrow putting the four sleeve in place.

subetealabici · #17 08-19-2011, 02:41 AM

The other thing is that I messure the top off the sleeve and the depth of the block groove, to see how much should be left wen the sleeve was all the way in, and all the number so far are matching up, block 4.6mm sleeve 5.2mm left outside .6mm

t walgamuth · #18 08-19-2011, 07:54 AM

Once you get them in all the way the top of the block is to be surfaced so they are flush with it.

1960mog · #19 08-19-2011, 09:56 AM

Nice,clean job on the sleeves. Seeing your setup makes me appreciate my press. No elbow grease needed here.
The sleeves advancing in steps is normal, getting worse the further they going in.
Like to see some pictures of the machining of the block.

TheDon · #20 08-21-2011, 08:27 PM

this just popped up local to me

http://tampa.craigslist.org/hil/pts/2482552922.html

I also want to get a 616 cheap and rebuild it

subetealabici · #21 08-24-2011, 12:55 AM

Well all the liners are in now, I'm getting a set up to re bore the cylinders now, that may take a bit of time, I'm also waiting for the piston rings to arrive.
I have some tools that I will be making for the honing, measuring, boring, machining, I will see how it goes

Stretch · #22 12-20-2011, 12:39 PM

How are you getting on? Is it done yet?

strelnik · #23 04-13-2012, 09:10 AM

Quote:

Originally Posted by Codifex Maximus

For a genset engine, you might also look into a Listeroid type diesel. They are so simple, reliable and speed governed that they are a third world fixture. It's said that they'll burn near anything and will probably be going long after most other engines are history.

I hear you can break one down and rebuild it in an afternoon.

You are absolutely right on the Listeroid engines, I think the biggest cost is shipping one from India. I don't know of any US distributor.

That doesn't mean that there aren't any, though.

subetealabici · #24 01-02-2014, 12:48 AM

So it take some time but I'm getting some progress on the engine rebuild, after moving to a new house and doing a bunch off stuff I'm finally making some progress with the engine long story short
We got a new place more than a year ago have a baby and time went by pretty fast
I also got a broken down lathe back in march that I fix up and use to make a boring machine from a radio arm saw and some square pipe.
So far in the past two weeks I finish the boring machine and make some tools for it, I re bore cylinder number 3 and cylinder number 2 I'm now boring the cylinder number 1 and so far the boring machine seems to be working fine, I went to far on cylinder 3 so I'm going to replace the sleeve.
Here some pictures, I will put down more details as I keep the work going,

subetealabici · #25 08-18-2014, 12:22 AM

It took me a couple off weeks to put the engine back together after boring the cylinders, and make some new tools to swap the old engines.
Timing is still a bit off and I may do some tuning on the IP and rebuild a set off injectors, over all the engine works pretty well.
I will post some pictures

leathermang · #26 08-18-2014, 05:03 PM

Quote:

Originally Posted by t walgamuth

Once you get them in all the way the top of the block is to be surfaced so they are flush with it.

Are you SURE about that ? I think I remember they are supposed to be a bit proud of the block... making them much more difficult to deal with..

subetealabici · #27 08-18-2014, 10:58 PM

After pressing the new liners I use the all in wonder machine to bore the cylinders to the 90.9mm size and then I ground the top off and finish the top with a very large file, this was more like a learn and test run

leathermang · #28 08-18-2014, 11:44 PM

Boring to a certain size is the way old American engines were put together... I think according to the manual you are supposed to measure the piston going into that cylinder and bore with respect to its size...

BillGrissom · #29 08-19-2014, 12:01 AM

Great work. I started on my failed 1985 617 engine a few years ago. I got the cylinder liners out easy once I found the cast iron split easy by forcing a thin screwdriver between the block from the bottom side. Some here pooh-pooh'ed that since "not in manual", "screwdriver might mar the block", and other foolish ideas. A little harder to get the new liners in. I heated the block over a propane stove and chilled the liners, but still had to use a sledgehammer on a steel plate above each. Perhaps should have sanded the block bores more and used oil. They started easy, but got harder about 1/2 way down. You can tell by the sound when they seat on the shoulder and stick up about the same as yours. I do have a 12-ton shop press, but didn't want to try rigging up the block in it. Stopped there, since next is paying a shop. I might also get a mill some day, and would be proud if I could finish it myself like you. I have another engine in the 1985 car, so this is just for fun.

t walgamuth · #30 08-19-2014, 06:46 AM

Quote:

Originally Posted by leathermang

Are you SURE about that ? I think I remember they are supposed to be a bit proud of the block... making them much more difficult to deal with..

Yes. I am sure. they are proud after being pressed in, then they mill the top of the block flush. We've done about six and always with good results. Never a blown head gasket in any of the engines and they are all still going strong as far as I know.