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#1
02-23-2013, 10:54 AM
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took my 603 apart and there's trouble in cylinder #2
The car smoked and ran rough, so I figured let's see what's up. only paid $750 for it...
#14 head, cracked between intake and exhaust valve cylinder #6. Head gasket blown near #1, oil passage leaking into cylinder. and on top of all this, rust in cylinder #3! I'll try to add a photo of this. Is it worth rebuilding the motor? crank and rod bearings all look like they've got a half million miles on them. could you just hone/ bore that one cylinder and go 40 over with the piston, and leave the other ones? (new rings of course) What would it cost to completely rebuild the long block, including chain? Anyone have a 603 I can buy?   
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#2
02-23-2013, 11:27 AM
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the rust is a sign the car sat with coolant in the cylinder for a long time...
40 over is a LOT are you sure a simple 10 over honing isn't availble?
__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread "as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do! My drivers: 1987 190D 2.5Turbo 1987 190D 2.5Turbo 1987 190D 2.5-5SPEED!!!  1987 300TD 1987 300TD 1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!
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#3
02-24-2013, 11:14 AM
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I have no idea actually. I do think 10 over would be fine. I guess you'd still need a new piston for that cylinder, right? It wouldn't make sense to hone all cylinders I would say, just new rings.
I have no idea if you can just buy a single piston, and what the cost of rings and bearings is for these motors. I heard they're expensive to rebuild. My W124 isn't ready to be scrapped yet!!
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#4
02-25-2013, 02:50 AM
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If you bore only one cyl, no matter .10 over or .40 you will then have to take your old pistons along with you new oversized one and have it weight balanced to match the others, not a big thing to do, but definitely a must. and if you are rebuilding the engine and putting new rings in,make sure that you do hone all the cylinders. otherwise it would be like putting new brake pads on and not turning the rotors, but more critical. if the new rings dont have freshly scored metel to rub against they will probably never seat and your car will suffer from power loss, non stop smoking and excessive crank case pressure. remember, these are very very high compression engines.
__________________
Live simply so others can simply live  07 E350 sport Wife's Daily 01 E320 sport My Daily 00 C230 Kompressor Our back up (new Arrival) 87 300D Turbo my Daily for 8 yrs. Selling to neighbor 82 GMC Jimmy (K5) 6.2 Diesel (my Wheeler) 73 Roadrunner 340ci My very first car, still own it
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#5
02-25-2013, 02:02 PM
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The early 603 blocks had removable cylinder sleeves.
Maybe this is an option on your engine.
__________________
 76 240 D. Bought in 1998 for $25. 85 300D. Got it for free with a bad engine. ( Sold ) 60 Unimog 404. What was left of it, was given to me. Now powerd by 617A. 88 560 SEL. Bought without engine and trans. Now powerd by 617A. 67 250 SE. Cuope. For resto or sale. 64 220SE. For resto.
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#6
02-25-2013, 11:50 PM
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Quote:
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#7
02-26-2013, 06:31 PM
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Quote:
If you are convinced that you want to do a "nice rebuild", be prepared to spend $4K by the time all is said and done. The replacement cylinder head is going to eat $2K of that to procure it and recondition it properly. All those who claim to do it for cheap haven't done a "nice rebuild". They simply did a cheap and fast rebuild that will get them another 100K.........maybe.
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