Cost of 603 Engine Rebuild - PeachParts Mercedes-Benz Forum

reinier · #1 01-16-2006, 05:26 PM

I have rebuild a couple of engines (couple of Renault, and a 2.3-16 MB)that are stille running well!), and I can say that the most expensive parts are the pistons.

Mostly, the bearings are very cheap, here in the Netherlands MB bearings were CHEAPER and faster delivered than aftermaket ones.
Expect max. 200-300 euros for bearings and oil simmer rings.
Oil pump ussually is not very expensive either (100 euros).

pistons for a turbodiesel are here available for 130-140 euros a piece, and 200 for a 'kitset' (i think this is with liner). Mahle brand, which is good. (I am talking aftermarket here, maybe MB is cheaper, you never know....)

Then you need the timing chain, sprockets, gaskets etc.

But again: in the engine you'll lose the most on pistons.

When the engine is still runing good, you only have to get the crank measured, and maybe polish it a bit, and its ok.
I dont think its doable if you have 2 left hands. I myself am a mechanic and specialised in man. gearbox overhauling (and a bit experience with overhauling engines), and have a workshop with most the tools (not the big machinery for boring out cilinders etc.), so i can do it in a couple of days.
But if you are a newbie to this, you'll:
-have to invest a couple of hundred in tools
-have to have a couple of weeks time
-have to go for several jobs to a overhauling company (like myself) for the expensive-machinery-work

In the end youll be saving a couple of grand i think.

Then a few remarks:
-what are shortblocks (and are there also tall blocks?) and what are the differences
-I thought because the 603 is a iron cast block, you dont need liners, just oversized pistons. ( a nephew of my woman is the main man for boring and honing cilinders at the company where i worked, I also can ask him why)

dieseldiehard · #2 01-16-2006, 05:29 PM

you all are wasting time on the subject of HGV's query re: rebuilding a 603, that was in 2003 and since then he had the engine stolen from his mechanics garage parking lot!

h46fixers asked about a rebuilt TURBO, and Brian's recommendations are good.
I've used Majestic in Waco (not the one in Dallas) and next time I will plan to give any business to Forced Performance, unless I try to DIY.

Hatterasguy · #3 01-16-2006, 05:30 PM

Shortblock= just the engine block with pistons crank ect already installed.
Longblock=same as above but with head and usually IP
Crate engine= new everything alt, waterpump, injectors, ect. Plug and play option.

The 603 uses sleeves, if you are going through the trouble of a rebuild you might as well install new sleeves along with the pistons. The new sleeves will need to be honed and bored.

reinier · #4 01-16-2006, 05:37 PM

Ah, thanks for clearing that one up.
For a moment I thought there were 2 kinds of engines of the 603....as in: different deck heights.

And for the sleeves: are they the same as liners?
The Mahle kitsets are: 1 piston, 1 set of rings, 1 piston-pen, and 1 liner

I am familiar with WET liners. They are used in a lot of french engines.
I have purchased a couple of kitsets from mahle, and they had the liners already honed at the size it must be.

dieseldiehard · #5 01-16-2006, 05:38 PM

Quote:

Originally Posted by Hatterasguy

Shortblock= just the engine block with pistons crank ect already installed.
Longblock=same as above but with head and usually IP
Crate engine= new everything alt, waterpump, injectors, ect. Plug and play option.

The 603 uses sleeves, if you are going through the trouble of a rebuild you might as well install new sleeves along with the pistons. The new sleeves will need to be honed and bored.

engine was stolen Henry has no interest in rebuilding it. forget this subject!
Subject raised was re: REBUILT TURBOS.
I suggest all this be started anew on ANOTHER THREAD!
DDH

reinier · #6 01-16-2006, 05:40 PM

oops yeah, sorry, now i see he posted his question in 2003.....

As far as turbo overhauling, a cant be of much help. i let other people do this. Dont you need a balancing machine to balance the thing doing 100.000 rpm's?

t walgamuth · #7 01-16-2006, 07:02 PM

who cares if it is ten years old?

the liners/ sleeves are steel. on this engine they are dry. they need to be pressed in and pressed out.

the turbo rebuild consists of taking it apart and replacing the bushings and seals. the turbo blade usuallly needs notheing. if it did you couldnt do anything with it anyway. no special tools needed. but the rebuild kit i got lacked the basic mounting gaskets so i had to wait while they came in.

tom w

blueranger · #8 01-16-2006, 08:15 PM

there is a place here in my town that specializes in
turbo rebuilds for diesels... yours will be a little small for them
but i think they can do it... 300 bucks..

the way i feel about a rebuild is to do it in stages....
right now i would take the head off and replace the rings with oversized
rings and I would do the lower bearings... this is all i would do...

go another 100k then replace the sleeves and pistons....

Hatterasguy · #9 01-17-2006, 11:56 AM

Quote:

Originally Posted by dieseldiehard

engine was stolen Henry has no interest in rebuilding it. forget this subject!
Subject raised was re: REBUILT TURBOS.
I suggest all this be started anew on ANOTHER THREAD!
DDH

I knew it was an old thread before I first responed.

dkveuro · #10 01-16-2006, 08:22 PM

Pistons can be reused if the motor has not been overheated or run out of oil.

Tip = Use a set of next oversize rings and file to get minimum end gap for each bore.
Better yet are, having your new 2nd groove rings machined at Total Seal.

http://www.totalseal.com/ About $60.00.

Engines done this way will have 450 to 525 psi cranking pressure.

.Remember, these engines will live for 600,000 miles or more....on the SAME pistons.

The wet liners are honed to size and are installed into a step in the lower block. The head holds the top of the liner in place. Mercedes uses a pressed in liner that needs boring to size after installed because it is a tight fit and this distorts the liner.

.