OM603 engine repair. Am I crazy?

[ah-kay]

Disclaimer: I am not a heavy duty engine guy but I would like to give it a shot and would like your comments.

The SDL oil pump chain snapped a few weeks back. The engine seized for lack of oil. I can hardly turn the engine even with the injectors removed. Shavings found in the sump, I think it is crank shaft bearing shavings. I took the head off today and take a look at the cylinders and they seem to be OK. I have never looked inside a diesel cylinder so OK means the walls are quite smooth and no deep scratches. There is some carbon deposit at the top of the cylinder wall, is this normal?

This is the plan.

1) Take off the oil pan
2) Replace all piston rings by pushing the pistons from underneath.
2) Replace all crank shaft bearings
3) Replace oil pump chains
4) Put everything back together and hope for the best.

Is it doable or am I crazy? Any comments are welcome.

[vstech]

you're crazy.

[vstech]

seriously though. oil loss seizures are massive undertakings to repair. doubly so with an inline 6 motor. the passages are thin and long, the crank is long, it's unlikely the sleeves are damaged much, but the lifters, cam, chain, guides, all inserts, the crank itself, rods... etc... all aare likely scored/twisted/gouged etc... it will hurt nothing but your time to inspect, but prepare for the worst.

[Diesel911]

You won't know if the Engine can be fixed until you have it apart and have looked at it.

As an example If the Crankshaft Journals are all rough and have melted Metal on them would keep you from just installing new Bearings.
The same if the Con Rod bearings are shot.

You just won't know until you look.

I have often mentioned the new Round Piston Rings going into an oval Cylinder Bore. You won't know until you measure the Cylinder Bore.

The ridge of Carbon at the top of the Cylinder is normal. It is also normal for there to be a Ridge of Metal there because that area does not wear and will likely be the size of the un-worn Cylinder A.K.A Ridge. On gassers you use a Tool called a ridge Reamer that cuts off that Ridge.

If you don't cut the Ridge off when you shove out the Piston there is a chance you can damage the Rings and or the Piston Lands.

If the Cylinder Bores are oval you might consider retaining the same Piston Rings and marking the position of the Ring Gaps as you pull the Piston out. You do not want to rotate them in the Groove if you can get away with it.

If you have not rebuilt any Automotive Engine before find some sites on the Internets and study up. Gasoline Engines have the same parts for the most part so the methods are similar.
Obtain a copy of the Factory Service Manual.

Part numbers for service Manuals STARTEK; Mercedes
Star Service CDs and DVDs
Contact Consumer Promotions at 1-800-FOR-MERCedes for current pricing and ordering information on the accompanying CDs and DVDs that are available for purchase. Please refer to Service Information S-B-99.00/222J for more on Star Service

[sixto]

Time and effort aside, price a set of crank and rod bearings and a set of piston rings and you'll think twice about the undertaking vs sourcing a good used short block.

Sixto
87 300D