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  #16  
Old 01-16-2019, 12:20 PM
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Hey Nate,

Looks like it won't be too bad to remove and replace the whole unit. There are plastic covers that keep dirt out of the engine bay that need to be popped off, and the whole thing should lift out (when all mounts are unbolted).

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Milan Brown 1979 240D, rebuilt OM617.952 turbo diesel, rebuilt 722.315 transmission (my only daily driver)

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  #17  
Old 01-16-2019, 01:38 PM
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Post Sway Bar R & R

BE GENTLE with those plastic covers ! only the right side is still available, they're cheap (under $6) and very important .
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1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better
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  #18  
Old 01-16-2019, 02:41 PM
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I will try not to damage them, but they are 40 year old plastic. I will try to pull the sway bar when the rain we are having lets up a bit.
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Milan Brown 1979 240D, rebuilt OM617.952 turbo diesel, rebuilt 722.315 transmission (my only daily driver)

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  #19  
Old 01-16-2019, 11:14 PM
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Yes, I understand having had a few crumble in my fingers .

If you're *very* gentle/careful even the broken ones come out without damage and can be re used .

You really don't want these gone missing .
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1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better
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  #20  
Old 02-11-2019, 11:15 AM
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I have gotten the OM617 back from the machine shop. The head was perfectly flat, did not need to machine it, but when I got it home, I realized my valve guides were worn way past their useful life. I have about 1/16" of play on each intake valve, so I will be putting in all new guides.

I stripped the old OM616 down. I still suspect a timing chain slip caused by engine failure, but can't be 100% sure. The block was picked up by a scrap guy. The OM616 head has what looks like a sunk valve, which explains my misfire.

At this point, I've made an itemized list of what I need to get my OM617 in and running, and it's over $2000. I am going to ask my second job for an advance so that I can get this build done in one go, and not have to keep the car and engine sitting around for longer than I need.

I did get the OM617 block masked up and painted, I am really excited to start getting it assembled. I also went out and had some paint mixed and put in a spray can so that I can paint the engine bay.



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Milan Brown 1979 240D, rebuilt OM617.952 turbo diesel, rebuilt 722.315 transmission (my only daily driver)

Instagram: @maximed93

Last edited by Maximan1; 03-01-2019 at 11:55 PM.
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  #21  
Old 02-15-2019, 05:33 PM
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Another update today, got to take advantage of the lack of rain. Local forum member DesertDunes let me stop by and make a template of where the expansion tank brackets are using his '85 300TD.



I used the template to mark out on my 240D where the brackets should be.



Used a grinder with a flap wheel to remove the paint + seam sealer.



And welded the new brackets in place.



Also put a bit of paint over the areas that were down to bare metal to prevent rust from this rain we have in the forecast.



Again, thank you Hunter (DesertDunes) for letting me use your engine bay to make my template.

Mobile welder would have charged me around $200 for the same job. I'm pretty pleased with my results, considering I'm using a $100 Harbor Freight gasless MIG.

Max
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  #22  
Old 02-16-2019, 12:51 PM
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Thumbs up Remote Surge / Puke Tank

Excellent ! .

I'd love to do this to my '82 240D .

Have heart, the rain is supposed to stop Monday Presisdent's day too if you're lucky enough to have the day off .
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1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better
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  #23  
Old 02-17-2019, 01:55 AM
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Thanks Nate. I'm happy with my progress but I do feel like I'm in over my head sometimes, but when I finish this project (not just the engine swap) I'm going to have the best 240D in Anaheim.

When this car is back to daily driver status, I want to repaint some panels (roof, door frames, trunk lid, driver rear door needs bodywork also), new carpet and upholster it to my with some nice fabric that I spent months tracking down (used to have a '78 VW bus that had custom upholstered seats I purchased, wanted to match the fabric), and put seat ventilation/heating in the fronts.

I figure I'll spend over $10K on this 240D by the time I'm finished, but I want it to be my daily for years to come and it's still cheaper than buying any new car.

Max
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  #24  
Old 02-17-2019, 09:57 AM
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Thumbs up The Right Attitude

Max ;

You're well on the way .

My very first Mercedes was a 1982 240D and it's still paked in the driveway, ready to go anywhere at the drop of a hat .

You're lucky in that there are two self service yards close by, both get in W123's regularly so keep an eye out for the cars you can grab little things you'll be needing off of .

One yard is seriously nasty, t'other not so much but both often have good parts .

The satisfaction of having this project a useful thing you created with your own two hands, is great .
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-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better
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  #25  
Old 02-17-2019, 10:25 AM
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Great thread. What are you using to post the large pics? Imgur?
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  #26  
Old 02-17-2019, 11:27 PM
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Quote:
Originally Posted by vwnate1 View Post
Max ;

You're well on the way .

My very first Mercedes was a 1982 240D and it's still paked in the driveway, ready to go anywhere at the drop of a hat .

You're lucky in that there are two self service yards close by, both get in W123's regularly so keep an eye out for the cars you can grab little things you'll be needing off of .

One yard is seriously nasty, t'other not so much but both often have good parts .

The satisfaction of having this project a useful thing you created with your own two hands, is great .
Thank you. I have notifications set up for all W123s in the yards around here, but I haven't had any luck recently. I am still kicking myself for not grabbing the pristine dashboard out of an 81 240D that was in the Katella yard when I just bought my 240D.

I had no idea that nice dashes were so hard to find, and by the time I made it back the whole car was crushed.

I got an advance from my second job, so I can get some parts ordered and get started with assembly. Very excited.

Quote:
Originally Posted by tyl604
Great thread. What are you using to post the large pics? Imgur?
Hey, thanks. I was using Imgur for the larger photos, but I started experimenting with other hosting sites. Imgur is not particularly mobile friendly, and all my photos are taken and uploaded via my smartphone. There was a moderator that would resize the photos I uploaded, but he stopped doing that a few posts ago.

Will update as progress continues.
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Milan Brown 1979 240D, rebuilt OM617.952 turbo diesel, rebuilt 722.315 transmission (my only daily driver)

Instagram: @maximed93
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  #27  
Old 03-01-2019, 11:46 PM
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Small update, waiting on more funds so that I can continue building the engine. Currently have the new main and rod bearings in and ready to go, but I need a gasket kit before I put it together any more (for the rope seal in the rear).

I am also waiting on 3 good used pistons in the mail from another member here - the pistons I got with the engine had a little too much damage to their faces, not worth running the risk of an engine failure because I kept the old pistons.

I am planning on doing some modification to the combustion chambers (removing the valve shrouding for better flow), and porting and polishing the head and manifolds.

I have been getting a little work done on the engine bay - scraped the old seam sealer (which was peeling up and cracking) out of the crevice underneath the battery tray, treated the area with naval jelly to remove the rust that had formed there, cleaned out the drain, and shot it with some self etching primer.

I intend to get as much done on the engine bay on Sunday as possible, hopefully I will have the bay essentially ready for a coat of paint by the end of the day.

I also picked up a nice little gig for a few extra bucks - the wheel repair shop next door to me asked if I'd like to come in from 4-5 PM Monday through Friday just to sweep up and help the customers that stop by while the owner/operator of the shop is out delivering wheels. Gives me a chance to get some work done on the car for an hour every day, and get paid for it too.

Here are the during and after photos of the rust under the battery tray - I seem to forget to take before photos pretty often.

No rust through, thankfully.



Nice rust free coat. I will be renewing the seal sealer in the engine bay anywhere that it needs to be renewed - I have the seam sealer that comes in a caulking gun tube, so I want to wait until everything is ready to open it up.



Max
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Milan Brown 1979 240D, rebuilt OM617.952 turbo diesel, rebuilt 722.315 transmission (my only daily driver)

Instagram: @maximed93
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  #28  
Old 03-02-2019, 10:38 AM
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Thumbs up

Looking good there .
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-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better
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  #29  
Old 03-03-2019, 06:30 PM
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Thanks Nate.

Got some more work done in the engine bay today. Looks like I will at least have to pull the upper control arm mount to remove the sway bay, there is almost enough room to get it out. I see now why this is a 13 hour book time job.

Other than that, I've got all the brackets and hold downs out of the engine bay. I will be getting them powder coated instead of zinc plated.
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Milan Brown 1979 240D, rebuilt OM617.952 turbo diesel, rebuilt 722.315 transmission (my only daily driver)

Instagram: @maximed93
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  #30  
Old 03-03-2019, 10:03 PM
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Post W123 Sway Bar

? why do you need to remove it ? .

The bushings go in with it in place, a 1/2 day job for a noob, after that it goes faster but you won't want to do it again .

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-Nate
1982 240D 408,XXX miles
Ignorance is the mother of suspicion and fear is the father

I did then what I knew how to do ~ now that I know better I do better
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