Engine rebuild with no former experience........

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30 Jan 2021 22:12 - 30 Jan 2021 22:15 #267692 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Both bell housings.

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Interesting that there are metal particles in the old transmission, you can see them here on the pump. The old transmission had also been given a bad silver paint job. It was originally married to a 350 engine that was in the car back when I bought it, it turns out both that engine and trans were trash.

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As the ball bearing had been treated to the metal particles I pulled it out, new ones are expensive from Mercedes but cheap from SKF, it is marked SKF 16008, a totally standard bearing.

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It popped out easily.

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I'm still waiting for prices for a replacement shaft, I will have to wait till Monday.

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Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 30 Jan 2021 22:15 by Racediagnostics.
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31 Jan 2021 21:49 - 31 Jan 2021 21:51 #267797 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Today I experimented with removing the stator shaft. I applied a bit of heat with a hot air gun.

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Then knocked it out from the rear using a socket.

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It came out fairly easily.

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Next I wanted to do a bit more cleaning on the transmission body but didn't want any debris getting in, so made up this blanking plate........

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.....and bolted it one with a bit of aviation permatex.

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I'm sure Kim wont mind me borrowing here tooth brush.

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Lots of brake cleaner later.

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Its not pretty but its clean......

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.......and still clean inside.

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Cheers
Jim

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Last edit: 31 Jan 2021 21:51 by Racediagnostics.
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01 Feb 2021 20:19 #267855 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Die grinder, wire brush and a corroded transmission, not for long.

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Then painted these steel parts.

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Un-peened the rear nut.

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This nut was on tight!

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Rear seal came out easily.

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New seals.

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Then an hour on the old gasket...........finally it was done.

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Shift lever reattached.

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Cheers
Jim

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01 Feb 2021 21:32 #267858 by KalliSL
Replied by KalliSL on topic Engine rebuild with no former experience........
Amazing !
Gruss aus Bruchsal

Kalli
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02 Feb 2021 14:44 - 02 Feb 2021 14:50 #267903 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi all, I'm confused about the transmission mount.

I'm pretty sure the one I fitted ten years ago is the wrong one as it seemed to be too narrow for the bracket.

The bracket has been spread out to be roughly parallel again below.

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This is the part that I fitted 10 years ago.

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This is the mount from my spare transmission.

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This is it's part number which seems to be NLA, A1152402118.

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You can see here that the OEM one on the left is taller.

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This is an extract from EPC with two part numbers for the rubber mount and metal cradle.

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Does anyone have a clue which is the correct part number for the mount that will fit the cradle I have.
Cheers
Jim

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Last edit: 02 Feb 2021 14:50 by Racediagnostics.

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02 Feb 2021 15:17 #267906 by gelberbenz
Replied by gelberbenz on topic Engine rebuild with no former experience........
Hello
Wow !!!

Werni

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02 Feb 2021 17:44 #267918 by BerndZimmermann
Replied by BerndZimmermann on topic Engine rebuild with no former experience........
Jim,

I am really looking forward to read about Your updates. Really eager to follow up.
However I would not be able to do half of the job.

So really curious what happens when the ignition is started first time after renovation.

Thanks for sharing.

Bernd
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02 Feb 2021 18:17 #267923 by Moerten
Replied by Moerten on topic Engine rebuild with no former experience........
Hi Jim,
I am really a Rookie doing stuff on my SL but I am learning. So I try to follow your impressive work. Looks like the mentioned transmission mount is available in 2 versions, as you already wrote. I looked at SLS-HH to learn and found out following:
There are 2 versions, a small and a wide one, what you already found out.
SLS- says, that the small one is used from 07/1972 after VIN 005814  THIS ONE
The wide one is the previous version  THIS ONE

I am not sure if this helps, but I am trying. Keep on showing your progress. I am keen to see it running again.
Gruß
Martin
_____________________________________
Lass mich, ich kann das... Oh, kaputt.
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02 Feb 2021 18:23 #267925 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi Jim,

the rubber mounting ... 2218 /  bracket .... 0140 is up to id-number: 023 001831 024 000015 043 008108 044 005813.
The rubber mounting ... 0413 / bracket .... 0340 is from id-number: 022 000001 023 001832 024 000016 042 000001 043 008109 044 005814.

Regards,
Lutz
Nur wer für den Augenblick lebt, lebt für die Zukunft.
Heinrich von Kleist
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02 Feb 2021 18:31 #267928 by mike 560
Replied by mike 560 on topic Engine rebuild with no former experience........
Hallo Jim
Iam a absolute beginner and i have problems with my blood pressure, when the pressure is falling down i look at youre photos and the pressure gets high.respect and sorry for my very bad english. Mike
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02 Feb 2021 20:51 #267947 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Post Brexit deliveries are taking a lot longer from Germany, I ordered this and a few other items from Autodoc back on the 13th Jan and it just arrived today.

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Removing the transmission front seal.

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Fairly brittle.

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Looks to be a couple of bearing/bushes to support the torque converter and drive shaft.

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Fits together like this.

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New seal back in place.

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Transmission end up for cleaning of the underside.

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All done.

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That is all I can do for now on the transmission, once the new bearing arrives I will put it back together and attach to the engine.
Cheers
Jim

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02 Feb 2021 20:52 #267948 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
On to the steering box.

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The first task was to mark the position of the "play" adjuster.

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Just enough space to get an Allen bit on to the steering coupler.

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The drag link was already loose from removing the engine.

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The nut on the pitman arm was not tight.

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Ball joint splitter on the track rod end.

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Arhhhh, my perfect paint!

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The pitman arm came off easily.

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Steering lock bolt ready to be fitted.

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Cleaned up.

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Ready to be stripped down, but I'd better check the instruction first.
Cheers
Jim

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03 Feb 2021 19:50 - 03 Feb 2021 19:51 #268035 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
On to the steering box, should be an easy half day job for a first time, or an hour second time round. So this is how it went.....

Pitman shaft driven out.

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That's a lot of seals to go in.

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Removing the front cover of the steering shaft showed this, a sheared bolt, someone has obviously been in here before me and did a bad job.

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Worm and piston removed.

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First I tried removing it with a centre punch, this has never worked for me in the past but I always give it a try before welding on a nut.

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Incredibly it was loose and came out.

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Next this circlip.....

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.... and removed this cap.

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Does anyone know if I can safely remove the parts below the cap, without small parts flying everywhere, I would like to put the entire body through a parts washer and remove all the old paint?
Cheers
Jim

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Last edit: 03 Feb 2021 19:51 by Racediagnostics.

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03 Feb 2021 20:01 #268038 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
That's a lot of seals.

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Pitman arm seals and O rings replaced.

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Next on to this nut.

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I held the nut in a vice and tried two different chain wrenches. both bent.

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Then a long lever but the nut was slipping in the vice.

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The solution was to drill a hole in a bar for the shaft then weld the bar to the nut.

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Two long levers.

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And its off.

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Hopefully tomorrow will go a bit smother.
Cheers
Jim

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03 Feb 2021 22:56 #268065 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi Jim,

maybe this helps.

Regards,
Lutz
Nur wer für den Augenblick lebt, lebt für die Zukunft.
Heinrich von Kleist
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04 Feb 2021 15:45 #268124 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Thanks Lutz, I had a look there and a few other resources and no one pulled it out, so I decided to leave it in place and rebuild the box.
Cheers
Jim

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04 Feb 2021 18:26 - 04 Feb 2021 18:33 #268147 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I completed the steering box today.

I was able to use these large circlip pliers to unscrew the front section.

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O-rings, circlip and seal to be replaced.

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Tightened the nut as much as I could.

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All complete.

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The parts in the top right are spare. I presume the kit covers a range of different boxes.

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The SLshop charge £ 450 to do this job!

www.theslshop.com/parts-shop/mercedes-be...vice-1074602101.html
Cheers
Jim

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Last edit: 04 Feb 2021 18:33 by Racediagnostics.
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05 Feb 2021 19:21 #268200 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
My 99p ebay win arrived.

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It was nice to have a bit of heat in the garage.

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New bearing fitted.

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Ready to install the pump.

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Next the filter.

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The new gasket.

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Permatex Aviation sealant on both sides of the gasket.

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Sealant on the lower 7 bolts as per the repair manual.

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Cheers
Jim

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05 Feb 2021 19:21 #268201 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Finally complete.

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Cheers
Jim

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06 Feb 2021 00:00 #268220 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi Jim,

why do you use sealant on the gasket? Shouldn't the gasket seal by itself?

Regards,
Lutz
Nur wer für den Augenblick lebt, lebt für die Zukunft.
Heinrich von Kleist

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06 Feb 2021 05:52 #268225 by Seewolf107
Replied by Seewolf107 on topic Engine rebuild with no former experience........
Well Lutz.....I thought the same on my transmission and I had to remove it twice for the primary pump paper gasket....

So I think Jim did the right thing. I think there is no danger if you use it very thin.
Grüsse Claus
1966 Plymouth Belvedere 383, 300D 1983, 280CE W123
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06 Feb 2021 11:58 #268240 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Lutz,

Kent at mercedessource.com recommended its use so I went with his suggestion.
Cheers
Jim

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06 Feb 2021 15:42 #268272 by Dieseldok
Replied by Dieseldok on topic Engine rebuild with no former experience........
Hello,

if the threads of the lower 7 bolts are facing the oil level of the gear box, the paper gasket cannot seal the threaded bolts.
Does anybody has a more detailed picture of the lower gear box area?

Paper basket will seal pump and gear box housing.
But the thread of the bolts will allow the oil to leak.

Just applying some sealant will do the job.

Would be interesting to see if the oil pump housing gasket of a leaky gear box does show traces of oil leaks.
If not the bolts are suspicious/ need to be sealed with sealant.

Kind regards

JP

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06 Feb 2021 15:58 #268277 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
This is how it looked when taken apart.

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Cheers
Jim

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06 Feb 2021 22:51 #268335 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Just a few odd jobs today before and afternoon of Rugby on TV, finally we beat England at Twickenham! First win there since 1983!

I am concerned about the control pressure lever, does anyone know if it is supposed to be twisted like this or is it damaged?

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The replacement transmission support arrived, it is the correct size unlike the old one which had a tube that was too narrow.

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Some more parts for de-rusting and plating/passivating.

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Cheers
Jim

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07 Feb 2021 19:53 #268415 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I bent the control pressure lever back into the correct shape today.

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I suspect the control rod may also be bent but will try it out in a few days when I mount the transmission onto the engine.

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I cleaned up the trans mount carrier today also.

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Citric acid.......

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Washed and wire brushed.

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I'll zinc plate and passivate once I have a few parts to do.
Cheers
Jim

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08 Feb 2021 20:28 #268480 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Well today's instalment is a bit embarrassing! I managed to make a big omission when building up the heads and I only noticed a week or so ago. Today it was time to remedy the situation.

Can you guess what it is yet?

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Exhaust manifolds off to help with access.

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Valves held in place with rope.

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Yes, so I could finally fit the valve stem seals, what an idiot!

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It took about 4 hours to get them all fitted.

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Cheers
Jim

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08 Feb 2021 22:43 #268491 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........

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Better now than after installation of the engine or even after the first start .....

Regards,
Lutz
Nur wer für den Augenblick lebt, lebt für die Zukunft.
Heinrich von Kleist
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09 Feb 2021 20:18 - 09 Feb 2021 20:20 #268538 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
First I spent some time clearing more snow, looks like another cold day in the garage.

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One of the things on my to do list was check the ignition timing, I wasn't too sure that I had set it correctly.

First check that the pointer on the distributer cog pointed to its mark. That was good.

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I had set the distributer with the arm pointing to the slot in the housing assuming it indicated cylinder 1 tdc.

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However that seemed to be pointing to cylinder 2.

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So I got my optoviser on and had a closer look. There was another mark that showed up better with a marker pen. Problem solved.

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Next a closer look at the valve timing. Crankshaft set to TDC.

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The right camshaft (viewed from the front) was spot on as it should be with new sprockets and chain.

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However disappointingly the right cam is slightly off.

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That equates to about 6 degrees at the crank, so about 3degrees at the cam offset, when lined up.

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The Woodruff key info below is a bit confusing, does anyone know if it refers to the cam angle or the crank angle?

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Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 09 Feb 2021 20:20 by Racediagnostics.

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09 Feb 2021 20:37 #268539 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I found this so the above table refers to the crank and the table below refers to the CAM, so I'll go for the 3 degree CAM offset key. Two are actually needed for the left (from front) CAM.

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Cheers
Jim

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