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  #1  
Old 01-29-2003, 05:48 PM
Zane Reese
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better to bore or re-sleeve?

I have a 83 240D with standard sleeves and pistons. Is it better to resleeve back to standard or bore the sleeves and put the bigger pistons?
How easily do the sleeves bore (hardness, etc.)?
Also, I have a Haynes repair manual. Are there better manuals and where do I find them.
Thanks,
Zane
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  #2  
Old 01-29-2003, 05:54 PM
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If the existing sleeves have the material left it will be more economical to bore them and go to the next oversize. They are no more harder to bore than any other engine. You do have a machine shop involved?
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  #3  
Old 01-29-2003, 07:01 PM
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Whoa,,,,, have you looked at the price of pistons compared to sleeves ? If your pistons are still good.. then it may be $800 more to get larger pistons as compared to resleeving to standard to fit your pistons...
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  #4  
Old 01-29-2003, 07:31 PM
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wow - my brain seems to be going away FAST. You are absolutely right Greg. I did not even think about the cost of pistons. And I am the guy that just purchased a whole nother used low mileage engine instead of five new pistons for the 1985 300D FOR THIS VERY REASON. Like Greg said - if the pistons are good just resleeve it to the original size.
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  #5  
Old 01-29-2003, 09:01 PM
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Hey, everyone has those types of moments once in a while!
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  #6  
Old 01-30-2003, 08:32 AM
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616 pistons are cheap compared to 617.95 pistons.

A re-sleeve is a cheap way to go but most of the higher mileage 616 engines I have disassembled had excessive wear in the top ring recess of the piston. I bet your pistons will be pretty worn.

The Mercedes factory shop manuals for the 616 engine are very detailed - if you are doing a rebuild I would get one fast. A chiltons manual will not cut it for this type of work.

My .02

Tim
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  #7  
Old 01-30-2003, 08:44 AM
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Yes.... I said " If your pistons are good" ..... you need to tear down and inspect before you make any big decisions about your course of action...
How much have you found 616 pistons for ?.. I am looking at this same process.... might do pistons and sleeves myself.....
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  #8  
Old 01-30-2003, 10:02 AM
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When I rebuilt the 240D a year ago I seem to remember I was able to get the pistons for around $85/ea. You will not notice any performance increase by going the next size up.
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  #9  
Old 02-03-2003, 10:24 PM
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I have a 1981 and price pistons recently-

Looks like the OE Konblshmitt pistons and a new sleeves are $104, the aftermarket Mahl pistons in OS were $98.

So, the price difference isn't that great. Prices on the sleeves should be about $25-30. The big thing is installation costs and I might add finding a machine shop that is capable(ie good equipment) to do your work. It will make the difference in it being like new or self-distructing in a short time.

If your pistons are not worn out(measuring ring lands) and there were no broken rings, new sleeves would be cheaper. If not, the node goes to aftermarket pistons assuming the bores can be cleaned up.

This is not a gas car, so no more fuel=no more power for the OS.

Michael
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83 300d
01 vw A4 TDI
66 Chevy Corsa
68 GMC V6 w/oD
86 300E
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  #10  
Old 02-03-2003, 10:31 PM
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Just one more reason to love these 240's...
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  #11  
Old 02-04-2003, 12:51 PM
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all good advice here - I recently bought new Mahle pistons with Goetze rings for my 82 300SD($675 for pistons and $155 for sleeves) after asking similar questions and checking available options. I went for all new and made a variation of a tool shown in Mercedes shop manual to press liners out. One of my liners was very tight coming out as it had hard carbon deposits on the outside of the sleeve(yes, against the basic bore of the block). I'm happy that I did go for all new when I got the pistons and saw that Mahle has improved upon the originals by casting a hardened insert for the upper compression ring. This may be worth looking into. Also, at leathermang's suggestion I called the people at Deves rings and they told me that they offer a ring set with a thicker upper ring (3.17 vs 2.98 they said). Maybe this would be okay for the 616 motor IF the upper ring lands are appreciably worn AND you can get them competently recut to the larger size AND the 2nd ring groove is OK
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  #12  
Old 02-04-2003, 01:01 PM
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TCane was the one that recommended the Deves rings to me... Those are some interesting options you discovered...
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  #13  
Old 02-04-2003, 01:01 PM
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Cool information....

I always knew those ring manufactures would make anything you wanted!! I'm sure for a turbo or a 603 engine where the pistons are more expensive-that's an option. Funny, though my old truck pistons everyone but one place priced me $650 (6 pistons) and I got them for $125. Not a Mercedes, just rambling information.


Michael
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66 Chevy Corsa
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86 300E
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