Originally Posted by carmel (Post 3115106)

I'm looking for a 1993 300D 2.5 turbo conversion kit for the turbo to change from electronic control to pressure control like the 603x 1987
Dave wheeler
Boise ID
435 817 5555

Originally Posted by whunter (Post 3088733)

The new oil pump was submerged in new oil, and spun until primed, left to soak.

The oil filter housing was installed, and torqued per FSM..

I use engine bearing assembly lube on all bearing surfaces.

Installed the camshaft light preliminary torque 20 inch pound.
Installed crankshaft, Crank and rod bearings light preliminary torque 20 inch pound.
Installed the crankshaft timing gear, timing chain and tensioner, and torqued per FSM..

With the engine upside down over the cleaned catch pan.
I fabricated an adapter for the oil pump to engine block feed, and attached a one gallon funnel.
Filled the funnel with fresh engine oil, left to set 24 hours.
Removed funnel adapter.
Mounted/torqued oil pump, splash plate, chain and tensioner arm/spring per FSM.
Torqued Crank and rod bearings per FSM.
Installed Rear Main Seal into cover
Installed and torqued the Rear main seal Cover per FSM.

Flipped the engine upright:
Torqued the camshaft per FSM.
Re-checked chain timing.
Installed timing cover.
Installed valve cover.

Flipped the engine up side down:
Installed oil pan with "superseded" new gasket, and torqued per FSM.
Installed oil pan Side cover new gasket, and torqued per FSM.
Installed new front main seal.
Installed vacuum pump, and torqued per FSM.
Installed harmonic Timing alignment bracket.
Installed woodruff key, harmonic balancer, and torqued per FSM.
Installed balancer PULLEY, and torqued per FSM.

Flipped the engine upright:
One gallon of oil added to engine.
Installed serpentine belt tensioner, and torqued per FSM.
Installed A/C and alternator bracket, and torqued per FSM.
Installed dipstick tube brace to cylinder head, and torqued per FSM.

Installed lift chain and attached engine to hoist.
Added two stabilization/control binder straps:
#1. From exhaust manifold/turbo body up to engine hoist chain (to control side tilt).
#2. both hooks attached to the hoist boom arm reinforcing strut, looped around the harmonic balancer pulley (to control front rear tilt).

Warning: Strap #1 can be ignored until one of the engine mount arms comes close to an engine mount.
Strap #2 will need many adjustments as you lower, to keep the engine near level.

Raise the engine until the engine Stand is almost lifting off the floor.
Unbolt the stand from the engine.
Remove the stand from working area.
Installed the flywheel, assuring it is FULLY seated to the crankshaft.
Installed the follower (torque converter mounting plate), assuring it is FULLY seated to the crankshaft.

Warning: if they are not FULLY seated to the crankshaft, it can cause the new bolts to cross thread (ruin bolts), or fail to find the hole.

Warning: Never reuse these bolts, they are torque to yield, work harden at the first use. The FSM is loaded with warnings because these fasteners typically BREAK shortly after the second use.

Installed the new bolts, and torqued per FSM.


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Originally Posted by whunter (Post 3207047)

It's back...

Owner called me about a Horrible noise from the starter???
I drove to his house.

Using 1 - 2 second cranks with a stethoscope:

* Upon cranking; There was a grind/clank/kachunk from the starter - flywheel - bell housing area.

* Something jammed - locked on the third crank attempt.

* It was hauled back to my garage.

* I put a socket on the harmonic balancer bolt, there is no motion in either direction.

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At this point, I am guessing:

#1. The transmission must come out for any confirmed diagnosis - repair.

#2. The flywheel is fractured and jammed.

#3. The torque converter mounting plate fractured and jammed.

#4. A catastrophic starter failure has somehow jammed the flywheel.

#5. The flywheel bolts have broken, causing unknown secondary issues.

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Originally Posted by Smoker (Post 3222707)

Is that pieces of lifter??

Originally Posted by vstech (Post 3222960)

the parts car engine I have here, looks identical to that pic, but the camshaft is shattered as well...
I think you can skip wanting mine...

Originally Posted by whunter (Post 3222980)

Well, I will continue looking.
Plan to pull the head when I have spare time.

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