How hard is it to rebuild a 5 cylinder turbo diesel engine. More importantly where would I get the parts to do it. Mine leaks oil out of so many places I figure it is the only way to fix it. Besides I was thinking about putting the engine into another vehicle. Like a Mustang or a small pick-up truck. Maybe an 80's Corvette....

You can buy the parts from this site. Rebuilding these engines is not for a novice, especially of you need to pull the cylinder liners and replace them.

If it's not your daily driver... It's ok half the work and truble of same age American diesel. And you not going to replace liners if you can get a diffrent block at your local pick and pull for $120. My 0.2c

Here is a list of engine rebuild threads etc...




OM616 and 617 Engine Rebuild threads


Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

If it runs good I would leave it alone and tackle the oil leaks one at a time and try to just fix them. You need to start by cleaning the motor so you can see where it all is coming from.

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[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.

You didn`t mention how many miles were indicated on the spedo of the vehicle it came out of. On a lot of these older MB`s the spedo`s are known to slip or totally quit, so that isn`t always a good indicator.

Adjust the valves, and then do a compression and leak down test to get an idea of the health of the engine.

As Tom said, fix the leaks. Leaks are not an indicator the engine needs a rebuild.
A few leaks over many years can cause a real mess of build up oil and crud.

Oil Cap, Rubber elbow top of Valve Cover, Valve Cover Gasket, Turbo Drain, and drain from Air Filter housing to pan are a few problem areas.

I posted the rebuild threads because you asked about rebuilding the engine, but really didn`t give any other info.

WHUNTER (ROY) posted a list of all the parts and part#s for rebuilding a 617 engine, but I`ll be danged if I can find it.
Harder to search for things that it use to be.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Car has about 400k miles and that is a low guess. It leaks oil out of the front of the engine the back of the engine the head, the valve cover, the oil pan. The whole bottom of the car is covered in oil. Plus anywhere I have ever stopped. It is impossible to stop the leaks without rebuilding the engine.

I do not want to drive the car anymore, but I would like to put the engine in something else.

Start by doing a compression test. If compression is good follow Toms advice and fix the leaks.

If it is indeed overhaul time there is no magic involved but overhaul parts are relatively expensive.

Changing liners is no big deal for a competent machine shop, but if you buy oversize pistons there is no need to change liners, simply bore to fit new pistons like any other engine. If pistons are in good shape, the machine shop can change liners and bore to fit original pistons.

__________________
2001 SLK 320 six speed manual
2014 Porsche Cayenne six speed manual

Annoy a Liberal, Read the Constitution

X2 on checking for low hanging fruit in the leak department first. It's amazing how much mess a simple to fix valve cover or breather leak can make. Air flow at speed sends the mess everywhere.

Give the engine a good bath (at the DIY car wash, bring your ramps, and don't be afraid to get dirty a la Mike Rowe) and then go hunting. You might get pleasantly surprised to find it is something simple. Even if it is not, you will be glad you cleaned the beast before trying to pull it.

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The OM 642/722.9 powered family
Still going strong
2014 ML350 Bluetec (wife's DD)
2013 E350 Bluetec (my DD)

both my kids cars went to junkyard in 2023
2008 ML320 CDI (Older son’s DD) fatal transmission failure, water soaked/fried rear SAM, numerous other issues, just too far gone to save (165k miles)
2008 E320 Bluetec (Younger son's DD) injector failed open and diluted oil with diesel, spun main bearings (240k miles)

1998 E300DT sold to TimFreeh
1987 300TD sold to vstech

X3 I use this for degreasing:

It is available at Sam's Club. There is no other product that works as well (it laughs at Simple Green!).

__________________

All Diesel Fleet
1985 R107 300SLD TURBODIESEL
2005 E320 CDI (daily)

LOTS of parts for sale!


EGR block kit
http://www.peachparts.com/shopforum/diesel-discussion/355250-sale-egr-delete-block-off-plate-kit.html

1985 CA emissions 617 owners- You Need This!
Sanden style A/C Compressor Mounting Kit for your 616/ 617 For Sale + Install Inst.

Sanden Instalation Guide (post 11):
http://www.peachparts.com/shopforum/diesel-discussion/367883-sanden-retrofit-installation-guide.html