OM616.952 Extreme Rebuild parts list

This list is based on a
1983
240D

THESE PRICES ARE SUBJECT TO CHANGE WITHOUT WARNING..
Call or e-mail Phil for current prices.




Gasket kit, short block-Engine Crankcase, includes Valve Cover Gasket
MB# # 616 010 55 06
$71.00

Cylinder Sleeve, (5 Per engine)
MB# 616 011 12 10
$34.00 each

Head Gasket Set, NOTE: Does not include Valve Stem Seals or Valve Cover Gasket.
MB# 616 010 52 21
$63.00

Intake Valve Guide, STANDARD, 14 MM
MB# 616 053 03 29
$6.78 each

Intake Valve Guide, REPAIR SIZE, 14.20 MM
MB# 616 053 04 29
$22.50 each

Exhaust Valve Guide, STANDARD, 14 MM
MB# 616 053 03 30
$6.84 each

Exhaust Valve Guide, REPAIR SIZE, 14.20 MM
MB# 616 053 04 30
$22.50 each

Seal ring, STANDARD SIZE, for setting diesel injection prechamber deck height = the CRITICAL GAP between piston and prechamber.
MB# 615 017 00 60
$1.23 each

Seal ring, SIZE 1 = 2.3 MM, for setting diesel injection prechamber deck height = the CRITICAL GAP between piston and prechamber.
MB# 615 017 01 60
$1.85 each

Seal ring, SIZE 2 = 2.6 MM, for setting diesel injection prechamber deck height = the CRITICAL GAP between piston and prechamber.
MB# 615 017 02 60
$2.00 each

Seal ring, SIZE 3 = 2.9 MM, for setting diesel injection prechamber deck height = the CRITICAL GAP between piston and prechamber.
MB# 615 017 03 60
$2.40 each

Prechamber, diesel injection
MB# 616 010 01 52
$206.00 each

Screw collar, injector mounting
MB# 615 017 00 03
$22.50 each

Washer, bolt cylinder head BOLT to block, (14 Per engine)
MB# 110 016 04 76
$3.00 each

Cylinder Head Bolt, (4 Per engine, stretch to yield, junk used ones)
MB# 615 990 01 12
$3.18 each

Cylinder Head Bolt, 10 X 120 mm, 12 Point Allen Head, (4 Per engine, stretch to yield, junk used ones)
MB# 615 990 02 12
$2.24 each

Cylinder Head Bolt, (6 Per engine, stretch to yield, junk used ones)
MB# 615 990 03 12
$3.06 each

Thrust Washer Set, (Shim) To Engine Main Bearings 2.15 mm
MB# 617 030 00 62
$24.00

Thrust Washer Set, (Shim) To Engine Main Bearings 2.20 mm
MB# 617 030 01 62
$32.00

Thrust Washer Set, (Shim) To Engine Main Bearings 2.25 mm
MB# 617 030 02 62
$32.00

Thrust Washer Set, (Shim) To Engine Main Bearings 2.35 mm
MB# 617 030 03 62
$32.00

Thrust Washer Set, (Shim) To Engine Main Bearings 2.40 mm
MB# 617 030 04 62
$32.00

Main Bearing Set, Standard 70.00 mm
MB# 615 030 05 40
$77.00

Main Bearing Set, repair size 69.75 mm
MB# 615 030 01 40
$90.00

Main Bearing Set, Standard 69.50 mm
MB# 615 030 02 40
$90.00

Main Bearing Set, Standard 69.25 mm
MB# 615 030 03 40
$90.00

Screw, pulley to harmonic balancer mounting, (6 per engine, stretch to yield, junk used ones)
MB# 000912 008047
$2.00 each

Dowel pin, harmonic balancer mounting, (2 per engine, get extra = single use and easy to damage)
MB# 000007 008244
$1.50 each

Spacer Ring, Front Crankshaft Seal
MB# 615 031 00 51
$11.00

Flywheel Bolt, automatic transmission, (12 Per engine, stretch to yield, junk used ones)
part # 110 990 04 19
$7.42 each

Flywheel Bolt, "MANUAL" transmission, (12 Per engine, stretch to yield, junk used ones)
part # 615 032 05 71
$6.50 each

Rod Bearing Set, Standard 52.00 mm
MB# 615 030 00 60
$74.00

Rod Bearing Set, Standard 51.75 mm
MB# 615 030 01 60
$74.00

Rod Bearing Set, Standard 51.50 mm
MB# 615 030 02 60
$74.00

Rod Bearing Set, Standard 51.25 mm
MB# 615 030 03 60
$74.00

Rod Bearing Set, Standard 51.00 mm
MB# 615 030 04 60
$74.00

BOLT, piston Rod Bearing Cap, (8 Per engine, stretch to yield, junk used ones)
MB# 615 038 05 71
$7.50 each

Wrist Pin Bushing, 29.00 MM, (4 Per engine)
MB# 621 038 19 50
$24.50 each

Wrist Pin Bushing, 29.5 MM, (4 Per engine)
MB# 621 038 20 50
$24.50 each

Piston, standard, (4 Per engine)
MB# 616 030 63 17
$374.00 each

Piston Ring Set, Standard (90.90 mm) 3.0 - 2.0 - 4.0
MB# 003 030 24 24
$35.00 per piston

Intake Valve, (4 Per engine)
MB# 616 053 03 01
$25.31 each

Exhaust Valve, 10 mm Shaft Diameter (4 Per engine)
MB# 616 050 00 27
$30.00 each

Valve Stem Seal Kit, (1 Per ENGINE)
MB# 615 050 00 67
$9.13

Valve Spring, (8 Per engine)
MB# 615 053 01 20
$5.50 each

Locking nut, valve adjustment, (8 Per engine)
MB# 153 990 02 51
$8.00 each

Nut, top valve adjustment, (8 Per engine)
MB# 615 053 00 72
$10.00 each

Bushing, valve rocker arm, (8 per engine)
MB# 615 055 01 50
$5.75 each

Rocker Arm, valve, (8 per engine)
MB# 616 050 03 33
$99.00 each

Tensioner, timing chain
MB# 615 050 08 11
$55.00

Chain Tensioner Rail, (Clamping Lever)
MB# 615 050 09 16
$35.00

Timing Chain Guide, NOTE: This Nylon Guide Replaces Two Previous Metal/Rubber Chain Rails.
MB# 615 050 14 16
$5.50

Timing Chain Guide, Lower - Outer
MB# 615 052 10 16
$3.58

Timing Chain Guide, Lower - Inner
MB# 615 052 11 16
$3.58

"IWIS" Timing Chain, With Master Link, Double Row - 136 Links
MB# 003 997 62 94
$131.00

Woodruff Key, 5 deg. offset. Camshaft Gear to Camshaft, To Adjust Valve Timing
MB# 621 991 00 67
$15.00

Woodruff Key, 3 deg. offset. Camshaft Gear to Camshaft, To Adjust Valve Timing
MB# 621 991 02 67
$13.50

Woodruff Key, 2 deg. offset. Camshaft Gear to Camshaft, To Adjust Valve Timing
MB# 621 991 04 67
$13.50

Woodruff Key, standard. Camshaft Gear to Camshaft.
MB# 006888 004002
$1.20

Bearing, intermediate shaft, (injection pump drive).
MB# 617 052 01 06
$53.00

Bushing, timing chain idler sprocket.
MB# 127 052 00 50
$8.75

Nozzle, diesel injector, (4 per engine)
MB# 001 017 29 12
$33.22 each

Diesel injector, (4 per engine)
MB# 002 017 15 21
$57.20 + core $11.90 each

Prechamber Heat Shield At Diesel Nozzle Tip, (5 Per engine)
MB# 601 017 00 60
$1.40

Glow Plug, Pole Type Element 12 mm Thread
MB# 000 159 83 01
$13.18

Engine Oil Pump
MB# 616 180 04 01
$488.00

Oil Filter Kit
MB# 000 180 25 09 67
$10.00

Repair Kit For Vacuum Pump, Piston Type, Includes Seals and Valves
MB# 000 586 17 23
$90.00

THESE PRICES ARE SUBJECT TO CHANGE WITHOUT WARNING..


.

__________________
ASE Master Mechanic
https://whunter.carrd.co/

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
2003 Volvo V70

https://www.boldegoist.com/

Since you are going to have to pull the engine if you want to deal with that piston. Plus all the otherwork. That used engine offered or another may become more appealing.

When it starts to get past a simple valve job this is the cheapest way to fly usually on these diesels. Sorry to see the additional damage . For some strange reason there are still a a fair amount of decent used engines around for this model. This may not last a lot longer though.

Wow impressive list! Do you have a total? My guess is around $1k

__________________
85 300D turbo pristine w 157k when purchased 167,870 July 2025
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Looks to me like something got into that cylinder and caused the damage, bending the valve and beating up the top of the piston. What was it? Prechamber ball? Where did it go?

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Here's a 0-60 video of my engine that's available. No oil leaks! Good compression and ran great.

Video somehow was deleted but here's a thread.

240D video 0-60

__________________
85 300D turbo pristine w 157k when purchased 167,870 July 2025
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

funola,

Thanks for the offer but I'm going to attempt to fix the engine I have. I have 2 motors and many parts from another 240d motor. I may buy another 240d that someone in my area is selling that has a bad motor. If I do decide to buy that car, I may be contacting you but that won't be until the spring.

Thanks again.

Pete

I have 3 good 240d pistons from another motor so I will replace the piston and order some new rings.

I guess I'll have to have the cylinder re-sleeved and bored.

The head is at the machine shop and they are check all the valves to see if any other ones are bent.

Why resleeved and bored?

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Kerry,

Isn't that required when you put new rings in a cylinder?

Should I just use my old rings that were on the damaged piston?

Thanks for the reply.

pete

You should replace the rings in my opinion but you don't necessarily need to re-bore. That will depend on outcome of the measurements you make... However, as you have the engine in bits I'd take that too to the machine shop and ask them their opinion...

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Thanks Army. I will bring the block to the shop. That thing is a beast to lift. Nothing like a steel block.

I got told off for lifting my block by myself - looking back I guess it is best to ask for some help and preserve your back for more athletic night time pursuits!

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

I would have had my machinist measure the taper and examine the bores, then if within specs he would hone it and install new rings on measured for wear good pistons after cleaning the ring grooves.

I would have him also look at the piston. It does not look that bad to me though, If he said it was good enough, I would have tried to clean it and just use the piston probably without tearing the short block down if the bores looked good.

__________________
[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.

Go to the link in this post, click on photos, the rod bearings are toasted in that engine + crankshaft is galled.
1983 240d zero compression #3 stuck intake valve


.

__________________
ASE Master Mechanic
https://whunter.carrd.co/

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
2003 Volvo V70

https://www.boldegoist.com/

As I resurrect an old thread....how was that broken valve guide diagnosed (before the obvious physical evidence was found). I still have my smoking issue and I *know* I put aggressive side pressure on the valve keeper to try to keep it from turning since I didn't have the third special tool.

I would not be surprised to find I broke the guide, but how would I diagnose that....other than pulling rocker and spring off?

__________________
Eric, CPO, Submarines, retired.
Here's a sig line...
Mine: '68 Corvette LS1/4L65E, 83 240D, 2000 GMC 4x4, 08 FLSTC Anniv
Hers: '72 Corvette 454/4spd, '99 MB SLK, '93 Metro vert, 78 240D, '92 Silverado, '65 Fjord Rustang, '59 Fjord Fairlane, '17 Slingshot.