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  #1  
Old 02-14-2019, 03:14 AM
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Join Date: Nov 2013
Location: San Mateo, CA
Posts: 705
‘Stormcloud’ – Cooling system remediation – Part 1

‘Stormcloud’s cooling system had been neglected by the PO, and required remediation before being used as a daily driver for my piece of mind.
The radiator leaked, the temperature gauge was not operating, and the water pump bearings were shot.
Green coolant was seeping from the climate control servo, the block heater, and various hoses.

Since ‘Desert Rose’ recently developed a turbo bearing failure, I had to press ‘Stormcloud’ into daily service sooner than planned.
I was not able to complete the full cooling system rehabilitation.
I still need to replace the fan shroud, coolant reservoir, reservoir cap, various hoses, and also work on the cabin heating system (which is bypassed for now).

Below is what has been done to ‘Stormcloud’ prior to the failure of ‘Desert Rose’s turbo seals:
The temperature sender, on the block between cylinder number 2 and 3, had very high resistance and a used PNP sender took its place.
This restored the temperature gauge function.
The radiator, heater core, and transmission oil cooler were bypassed to allow for a thorough flush, de-oiling, and citric acid flush of the engine.


Next, the water pump housing, and thermostat housing were removed, and treated with a weeklong Evapo-Rust soak to remove corrosion.
Scrubbing with a nylon brush removed the converted aluminum oxides.
Repeated soaks of the parts in a citric acid solution softened the heavy scale buildup, allowing it to be removed with a nylon scraper
Not all of the scale dissolved even after one month of soaking.
Attached Thumbnails
‘Stormcloud’ – Cooling system remediation – Part 1-radiator-bypass-citric-acid-flush.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-water-pump-housing-thermostat-housing-removed.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-parts-prior-de-rust-de-scaling-treatments.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-scale-corrosion-thermostat-housing.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-parts-after-de-rust-descalig-treatments.jpg  

__________________
79 300SD 'Stormcloud' new as of 10/22/2017
78 300SD 'Desert Rose' new as of 01/26/2014
83 300SD 'Rena 2.0' with engine from 82 300SD 'Rena' (SOLD & crushed 11-20-2017)

Last edited by Alec300SD; 02-14-2019 at 03:31 AM.
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  #2  
Old 02-14-2019, 03:18 AM
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Join Date: Nov 2013
Location: San Mateo, CA
Posts: 705
Below is what has been done to ‘Stormcloud’ to get her operational after the failure of ‘Desert Rose’s turbo seals:
There was some surface pitting at the water pump housing hose nipples and thermostat housing hose nipples that were smoothed out with some 400 grit sandpaper.

Gasgacinch was used to coat both sides of the paper gaskets used to seal the thermostat housing to the block,
the water pump housing to the block, and the new (rebuilt) MB water pump to the water pump housing.

A smaller diameter 1985 water pump pulley, shorter 1005mm alternator belts, a short 4 ply silicone hose to connect
the water pump housing and the thermostat housing, a new 9 blade plastic fan, and a new-ish PNP fan clutch were installed.
Attached Thumbnails
‘Stormcloud’ – Cooling system remediation – Part 1-water-pump-housing-gasgainch-coated-gasket.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-water-pump-housing-reinstalled.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-rebuilt-mb-water-pump-mb-star-7-oclock.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-thermostat-housing-shortconnector-hose-water-pump-installed.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-new-old-thermostat-gasket.jpg  

__________________
79 300SD 'Stormcloud' new as of 10/22/2017
78 300SD 'Desert Rose' new as of 01/26/2014
83 300SD 'Rena 2.0' with engine from 82 300SD 'Rena' (SOLD & crushed 11-20-2017)

Last edited by Alec300SD; 02-14-2019 at 03:38 AM.
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  #3  
Old 02-14-2019, 03:23 AM
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Join Date: Nov 2013
Location: San Mateo, CA
Posts: 705
A used PNP radiator re-cored by San Leandro Radiator was installed.
The system was filled with a 50/50 mix of Zerex G05 coolant and distilled water.
New flexible transmission oil cooler lines were also installed.
A pressure test was performed, and there were no fluid leaks.
The system held 15 psi for 20 minutes.

‘Stormcloud’s heater core is bypassed for now, so no cabin heat until “Desert Rose’s turbo oil leak is fixed.
Operating temperature for ‘Stormcloud’ has been about 175 degrees F on the daily commute this past week.
More updates to come…stay tuned.
Attached Thumbnails
‘Stormcloud’ – Cooling system remediation – Part 1-radiator-oil-cooler-being-reinstalled.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-hoses-reconnected.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-radiator-retaining-spring-installed.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-new-ish-fan-clutch-manufactured-nov-2007.jpg   ‘Stormcloud’ – Cooling system remediation – Part 1-pressure-testing.jpg  

__________________
79 300SD 'Stormcloud' new as of 10/22/2017
78 300SD 'Desert Rose' new as of 01/26/2014
83 300SD 'Rena 2.0' with engine from 82 300SD 'Rena' (SOLD & crushed 11-20-2017)
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  #4  
Old 02-14-2019, 07:59 AM
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Join Date: Dec 2018
Location: Huntsville, Alabama
Posts: 53
Excellent work! I enjoy seeing seeing clean repairs like you’ve performed.
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1998 E300 Turbo Diesel, 187k Miles
2018 Chevrolet Colorado Z71 4X4, V6, 7500 Miles
2007 Honda CRV, 110k Miles
2011 Kawasaki Trans Mule, 200 hrs, (grandkid hauler)
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