I wonder if it would be worth it or mechanically sound to mix-and-match pistons that are used, but good, and then resleave. I thinkj it would be a lot cheaper, but maybe a pain to try to salvage 5 pistons in excellent shape from a junk yard or somewhere. Would this be a good idea?
Thanks,
Adam

It is definitely CHEAPER to utilize used pistons and sleeve back to standard bore. That said, the piston in any diesel engine is a HIGHLY STRESSED piece. I have a souvenir piston with ring land failure.

It would cost a little more, but would give you a much stouter rebuilt engine by purchasing new oversize piston and simply rebore to that oversize.

Because these engines have liners, it is a common belief that you must replace the liners. Not so. The liners can be bored to oversize as with most any engine.

Good luck,

engatwork

"It was allot less than $3k "

I should have mentioned that I had to have the crank ground then everything balanced. That price also included new starter, clutch & p/p, radiator, allot of things that are not normally included in a rebuild price. I figured I could use the good, but replaced items for spars. It needed liners so I got oversize pistons and had the liners bored. I am rebuilding another 616 now but it only needed to be bored to fit the new o/s pistons. No crank work, This engine will cost much less than the first one. I think under a grand.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Turbo pistons are ALOT more than the non-turbo 616 pistons.

This issue frequently causes owners of higher mileage 617.95X engines to shy away from rebuilds while 240D owners can get a whole set of pistons for the cost of 2 617 turbo pistons. OM602 pistons are something like $350 per copy.... when my OM602 needs a rebuild it will be tradein time for me!!

I agree with Jim - a junkyard engine is a crapshot. If it works you will be way ahead $$$ - at least for awhile.

I can understand why people don't want to spend 3-4K for a proper rebuild when the entire car (even with a fresh engine) will only be worth 5-6K.

Tim

Here's what I'm thinking. Yes- the pistons are expensive. What I find interesting is that the oversized pistons are actually less expensive than the stock sized units. I'm not quoting exact numbers, but the stockers are something like $1050 for a set. The first oversize (0.6mm overbore I believe) are something like $885 for a set. I'm used to buying Chevy pistons, where I can get a whole set of 8 for less than $200.

That being said, if my liners will clean up with the 0.6 mm overbore, then I'll have the sleeves bored, buy the new pistons, rings, bearings, gaskets, timing chain, and miscellaneous odds and ends, re-assemble it myself, and hope to have a "fresh" engine for somewhere between $1500 and $2K. I'll have the machine shop tell me if I need a valve job, and spend the extra $200 or so if I need to.

None of the local junkyards have a suitable donor engine, and I don't want to put my faith in any Ebay engines or used pistons.

This is a good discussion, and highlights the many schools of thought related to engine rebuilding/replacing and vehicle value.

For now, I'm going to take the "Do it right the first time, and only cry once" philosophy. I hope to have the engine and tranny pulled out by the weekend.

SteveM

I'm a bit shocked at the price of M-B pistons. I did a comparison with Cummins for the heck of it and I found prices for in-frame and overhaul engine kits that were less than what just the pistons cost for a M-B. I always used to think that M-B prices were high (the main reason why I had stayed away from M-B's for so long) and this seems to reinforce my reasoning.
BTW the Cummins in-frame and overhaul engine kits include:
Cylinder Kits (available in standard and oversize) or Piston Kits
Connecting Rod Bearings (available in standard and oversize)
Main Bearings (available in standard and oversize)
Thrust Washers for In-Frame kits (where applicable)
In-Frame kits include In-Frame gasket set
Overhaul Kits include complete gasket sets for overhaul (including crank seals)
The least expensive set was $495 while the most expensive was $1950.
I would have thought Cummins parts would have been more expensive by far. I guess not.
The web site I used was:
http://www.maesco.com/products/fpd/fpdcummins/fpdcummins.html

I've rebuilt a number of engines from different automakers in the past and I never had one that cost me more than around $500 for a complete overhaul. None were diesels though.

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DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012