can anyone give me a general idea of the cost of the parts to do a complete rebuild for a 74 240 D engine? and also general cost of machine work needed ,plus best source of parts , I'm sure there's a lot of variables from engine to engine and where a person gets his machining done I'm just looking for a ballpark figure . Thank you in advance.
William Rogers..........

you do yourself I would tend to guess around $2500.
Jim

William,
Last summer I rebuilt a 1982 300D-turbo engine plus the turbo for about $1500. I got a good price on new Mahle pistons $95/each. The head did not need any work and the injection pump was good. The machine shop bill to remove the old sleeves, install new sleeves and bore for pistons was $175. These prices do not include any labor(all mine).
You should be able to get most of the parts from the Shop Forum. If not, let me know and I'll send you a list of half a dozen places you can get parts.
Bill Lewallen; Lexington,Ky. Where diesels purr and turbos whirr.

william,
i rebuilt my '77 240D this past winter. the '77 is the first year with the w123 body style, and the newer engine, but these figures should get you close. i replaced nearly EVERY moving part, plus some. (camshaft, pistons, cyl. sleeves, maina nd rod bearings, all valves, timing chain....the list goes on and on). parts ended up costing roughly $1000, machining was about $600-700. laybor was nothing because i did it myself. hope this helps (the car is running stronger, quieter, and less odorous than ever)

Assuming you do not do the Pistons or linears I went right here from this site to the fast lane catalog and got this list of most comon parts while doing this engine, Have fun

Head Gasket Set 616 010 52 21 $36.63 $36.63
Chain Tensioner 615 050 06 11 $42.53 $42.53
Clamping Chain Rail 615 050 09 16 $21.24
Lower Gasket Set 616 010 55 06 $47.71
Main Bearing Set Std. 616 030 05 40 $58.59
Rod Bearing Set Std. 615 030 00 60 $19.36
Sliding Chain Rail 615 050 14 16 $3.37
Sliding Chain Rail 615 052 10 16 $2.00
Sliding Chain Rail 615 052 11 16 $2.40
Timing Chain 003 997 62 94 $85.94
Piston Ring Set Std. 001 030 27 24 $131.91


Sub Total before shipping $451.68

Dr. parts,
Since you were using std. size rings, were the ring grooves not worn? Did you have new sleeves installed and bored for the old pistons? How about the oil pump. Was it replaced? Did you replace the water pump? Injection pump?Just curious.
Bill Lewallen; Lexington,Ky.