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  #1  
Old 09-23-2002, 12:32 PM
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Join Date: Sep 2002
Location: Saskatoon Sask. Canada
Posts: 21
Question rebuilding a 603.961

I'm looking into rebuilding this engine and I was wondering if anyone has ever compiled a list of parts requied to do this job?
I realize that the block will have to go in for boring and the head for milling but what about all the little things that you forget about and end up doing repeated trips to the parts store for?
Or for a job of this size do you just order everthing you can thing of and return everything that you don't use?
Any help would be greatly appreciated
thanks
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Don
87 300D
485k km
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  #2  
Old 09-23-2002, 02:31 PM
LarryBible
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You are on the right track, but it is always impossible, and actually unwise to order parts before disassembling and examining/measuring.

Once the engine is apart, you need to take the head for valve job, always including valve guides. DO NOT mill this head unless it absolutely needs it, which it probably will not. This is a diesel with a VERY SMALL combustion chamber, and it is iron, rarely needing to be milled. If it is a little unstraight, the machinist must proceed very carefully.

Secondly, mic the crankshaft to ensure that it will take standard size bearings which it probably will. The last engine of this type I took apart, I was able to reuse the original bearings.

You will then need to let your machinist test the block by seeing that it will clean up at a diameter less than the first oversize. At this point you will know whether to get pistons/rings in first of second oversize. Make sure you buy the pistons with the correct piston crown shape. There are two different types and they will not interchange without changing to the appropriate prechamber. Be careful with this.

Some people reuse the pistons and resleeve the block back to standard. If the pistons are in VERY GOOD condition you might get by with this. I personally do not prefer this method given that the pistons in a diesel are highly stressed.

I would plan for

reboring
pistons/rings
bearings,
timing chain, and associated parts,
head work

Good luck,
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  #3  
Old 09-24-2002, 10:24 AM
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Join Date: Sep 2002
Location: Saskatoon Sask. Canada
Posts: 21
Smile

Thanks Larry
Looks like you have done this once or twice!
The only thing extra will have to do is mill the head because it is aluminum and they do tend to warp when removed.
I,ve just completed a head gasket on my car and they removed .005' just to clean it up.
It looks like I found a used engine with 340-390lbs compression. It's a 603.960 engine but I think it can be used in the 300 sdl.
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87 300D
485k km
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  #4  
Old 09-24-2002, 10:59 AM
LarryBible
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boeing,

Well I offer my embarrassment because I did not read that this was an '87. I have done 616 and 617 engines which are the previous generation with an iron head.

I am not sure that the sleeve issue applies to your engine. If it does, then all that holds true.

The one useful thing I might offer on the aluminum head engine is that you don't want to mill the aluminum head, or any head on a diesel. The combustion chambers are microscopic and much loss of size will create too much compression. If you can't straighten it with about .010" or less, you will have to replace the head or have it bent in an oven.

A good friend of mine had one bent for his daughters car, and it ended up blowing the head gasket a few thousand miles later. This was such a shame because she ended up having to abandon the car.

Sorry for not reading all the post.

Good luck,
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