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

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09 Feb 2021 21:05 #268540 by Gezipfe
Replied by Gezipfe on topic Engine rebuild with no former experience........
Hello jim
KW refers to crank angle
Your decision with 0267 = 3 degrees is correct
Viele Grüße aus Neuenburg am Rhein
Gerhard
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09 Feb 2021 21:14 - 09 Feb 2021 21:17 #268541 by Seewolf107
Replied by Seewolf107 on topic Engine rebuild with no former experience........
Hi Jim,

I had the same issue on my 560 - I chose the 8 KW Degree on mine on the passenger side and it made such a huge difference!

I always had a little bit of shaking in the idle - it is completely gone and the engine stands still like a Rock in the idle.
 
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Grüsse Claus
1966 Plymouth Belvedere 383, 300D 1983, 280CE W123
Last edit: 09 Feb 2021 21:17 by Seewolf107.
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09 Feb 2021 21:36 #268542 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Next! The brake booster.

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I took the driver seat out.

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I also took out the lower kick panel to be able to see the brake booster fixing better.

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The pedal was connected to the booster by a bolt and this bush.

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It was relatively easy, with a bit of body contortion to get access to the four fixing nuts.

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Releasing the three brake pipe unions allowed it to be lifted out.

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Cheers
Jim

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10 Feb 2021 20:38 #268618 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
This morning I realised that the crank bolt could be fitted before the harmonic balancer and the pulley so fitted that, now I can get the engine off the stand and fit the transmission before getting the other parts painted.

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That is tight.

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I also ordered up the offset Woodruff keys so will wait to get these fitted before fitting the transmission.

Back to the engine bay, stripped out these parts....

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..... then all the wiring, clips, cable ties, blanking plugs and brake pipes.

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The wiper motor still has to come out, so I removed the glove box for a look. Just one nut and bolt on the motor link to the mechanism. and three nuts for the motor.

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That will take a bit of contortion tomorrow to get out. Then it will be on to a massive clean up and degrease to prepare for paint.
Cheers
Jim

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14 Feb 2021 14:19 #268815 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The garage has been off limits for four days now as its been below freezing out there day and night, however its due to warm up later today at last.

In the mean time....I printed out a degree wheel.......

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....then stuck it to the harmonic balancer. I removed the springs from two old hydraulic compensators, these will be used rather than the manual compensators called for in the repair manual to check on the CAM timing.

By chance the harmonic balancer is A4 sized.

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Cheers
Jim

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15 Feb 2021 19:36 - 15 Feb 2021 19:45 #268904 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
First I set up a pointer to check on the TDC marker.

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Then I made up this plunger to fit in the spark plug hole. Two attempts to get the thread right, a balls up with the change gears.

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With this in place, it allows the piston to be raised CW and CCW to give two readings. The tool needs to be removed while the engine is being turned over otherwise it will clash with the valves.

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30 degrees from one side.

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28 degrees from the other side.

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Splitting the difference then adjusting the pointer gave this. So the pointer on the water pump is ~1 to 2 deg out.

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Cheers
Jim

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Last edit: 15 Feb 2021 19:45 by Racediagnostics.

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15 Feb 2021 19:37 - 15 Feb 2021 20:12 #268905 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Next I removed the hydraulic lifters form cylinder 1 and 6.

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Then replaced them with old lifters with the spring removed and adjusted to take out any slack from the rocker arm.

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Dial gauge set up on Cylinder 6.

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With 2mm of valve lift the angular rotation ~6.5deg which is exactly on spec.

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With 2mm of valve lift on the right side the angular rotation is ~ 6 deg vs 6.5 deg target.

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www.youtube.com/watch?v=hlpfkts-iVQ

www.youtube.com/watch?v=r6aBAgOLGIY

The conclusion is, I don't need any woodruff keys and the CAM tower markings are approximate only.
Cheers
Jim

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Last edit: 15 Feb 2021 20:12 by Racediagnostics.
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16 Feb 2021 18:11 #268967 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Some painting today, wow it got to 10degC. The snow is melting fast.

Etch primer.

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Power steering pump.

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2K black.

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Trans sump pan.

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All done.

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The brake booster was originally black but the only brake fluid resistant paint I had was this silver and I like the contrast. A new one would be nice but they are £300.

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Onto the brake fluid reservoir, I put it in hot water to soften the rubber grommets to make it easier to pull off without damage.

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Then cleaned it up, again I will reuse as the replacement are a few hundred pounds.

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Cheers
Jim

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17 Feb 2021 21:11 #269013 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The first job today was to paint the legend on the balancer with silver paint and a scribe.

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I then looked up the torque for the M8 bolts to hold the pulley and balancer to the hub, it was 35Nm, that seems high for a M8 so I had a look for the old bolts and found four of the six.

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Aha... 10.9 bolts. I will get some new ones ordered.

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PS pump mounted.

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Then the water pump pulley.

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Transmission pan fitted.

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Brake booster reassembled.

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CAM oiler pipes fitted.

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Next I had a look under the baffle on the CAM cover with an inspection camera, there was a lot of crud under there. I think I will have to remove both for cleaning. Its a pain that they are blind riveted in.

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Cheers
Jim

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17 Feb 2021 21:12 #269014 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The engine ignition ECU has an aluminium/zinc body and a steel top, I will remove the lid and plate/passivate.

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Very old school.

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Cheers
Jim

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17 Feb 2021 23:22 #269018 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
God, you have worms in your ignition module! Probably the highly dangerous copper worms. I would recommend a treatment with hexavalent chrome .....

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Regards,
Lutz
Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
Samuel Butler
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18 Feb 2021 18:25 - 18 Feb 2021 18:28 #269095 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I was able to remove the windscreen wiper motor via the glove box in the end. Easier than expected. 

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Then onto remove the bulkhead insulation, not such an easy job. 

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It is a bit of a mess, I can't see myself reusing it, I will price up a new one tomorrow morning. 

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 There are couple of areas of rust, but not too bad. I will clean them up tomorrow but don't think I'll need to do any welding. 

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 Getting close to be able to paint. 

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Cheers
Jim

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Last edit: 18 Feb 2021 18:28 by Racediagnostics.
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19 Feb 2021 20:51 #269207 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Didn't get into the garage today, but went to the Mercedes dealer to pick up a few new parts and order a new bulkhead heat shield, £170 for a sheet of bitumen. :o

Throttle bulkhead gasket.
Offset woodruff keys which are now redundant.
10.9 strength bolts for the harmonic balancer.
Special lock nut for the steering box adjuster.

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Then I got dragged into the garden to do some pruning, once the green bin was full there was no alternative to getting a fire going.

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Then a few drinks as a reward, cheers!

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Cheers
Jim

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19 Feb 2021 21:40 #269211 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Here is a question, can I remove the four main front subframe nuts and bolts with the car sitting on its wheels, without anything falling off / collapsing? I plan to do a bit more plating this weekend and would be handy to do them at the same time.
Cheers
Jim

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21 Feb 2021 23:21 #269412 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I've been plating for the last couple of days, it's like waiting for a kettle to boil, then another one, then another one........

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The subframe bolts came out no problem.

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Looking better now.

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Cheers
Jim

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21 Feb 2021 23:25 #269413 by gelberbenz
Replied by gelberbenz on topic Engine rebuild with no former experience........
Hallo
Du galvanierst selber ???
Grüsse Werni

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21 Feb 2021 23:55 #269415 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Yes, these are some of the parts in the plating tank.

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Cheers
Jim

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22 Feb 2021 07:44 #269419 by T-Modell
Replied by T-Modell on topic Engine rebuild with no former experience........

Racediagnostics wrote:  it's like waiting for a kettle to boil, .......
 

Hi Jim,
I think the better expression would be "it's like watching paint dry" in a more literal sense. Amazing, what you do. And all this on a lonely island without permanent supplies ;-) ... hats off!

Thomas
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22 Feb 2021 18:27 - 22 Feb 2021 18:58 #269475 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Next, back into the garage!

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This area is the biggest concern.

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The tools.

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This looks bad, I wish I had a better understanding of how this fits together.

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It was easier to strip most of the paint rather than just try to remove the old contact adhesive.

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Ready to remove the bonnet.

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Kim is very tolerant!

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I think I will cut out the spot welds and peel back the "tabs" and then cut out the corroded area.

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Cheers
Jim

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Last edit: 22 Feb 2021 18:58 by Racediagnostics.
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22 Feb 2021 19:04 #269478 by wusel-53
Replied by wusel-53 on topic Engine rebuild with no former experience........
Jim, my Wife would kill me 

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Viele Grüße

Thorsten

Man lernt nie aus
380SL (US-Version, Bj.84), Eura-Wohnmobil und ein ebike :-)
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22 Feb 2021 19:39 #269481 by Thomas2509
Replied by Thomas2509 on topic Engine rebuild with no former experience........
Thorsten, why? The flowers are on the table and I suppose they ar from Jim:-)
Es grüßt herzlich
Thomas

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22 Feb 2021 20:00 #269482 by mike 560
Replied by mike 560 on topic Engine rebuild with no former experience........
Hallo Jim

youre wife is a dream,respect.

Mike

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23 Feb 2021 15:54 #269511 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I have this old picture showing the inside of the box section showing the flange in the top left area.

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Just beyond the inner wing.

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So went ahead and cut out this section.

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I decided not to disturb the tab from the chassis rail and instead build up this area with weld supporting with a copper pad.

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Paper template.

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I used 2mm steel for the repair.

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Cut and shaped.

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Fine tuned.

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Welded in.

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Cheers
Jim

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23 Feb 2021 15:55 #269512 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Tidied up.

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The box section treated with Dinitrol ML.

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Cheers
Jim

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24 Feb 2021 20:53 - 24 Feb 2021 21:00 #269638 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
This morning I removed the anti roll bar to give better access for painting, ideally I would remove the subframe too but I want to be able to roll the car back out of the garage a bit for painting so I will just mask it up.

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Next I decided to install riv-nuts for the ignition ECU mounting bracket, better than trying to reach round to fit nuts.

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Finally a job I think I've been putting off for a while, cleaning the engine bay. Degreaser first, then I'll sand it to give a key and then clean again with thinners. Boring and will take a couple of days to complete as there is lots of baked on grease.

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This section above the radiator looks like its never been cleaned in the last 42 years.

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That looks better.

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Probably no update tomorrow as it will just be more of the same.
Cheers
Jim

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Last edit: 24 Feb 2021 21:00 by Racediagnostics.
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26 Feb 2021 21:17 #269829 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
After a couple of days of preparation the engine bay is ready for paint. I will use an epoxy primer then basecoat and clear.

A few new supplies I had to purchase today, unfortunately I had no masking paper or film left, these will last me a lifetime.

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The car was originally Magnetite blue but when I first started respraying it back in 2016 the colour spectrometer matched up Lada Sapphire blue as a closer match, so I have stuck with that since.

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The bad news is that the weather forecast is cold (less than 10degC) for the next two weeks, so the painting will have to go on hold.

In the meantime I will push ahead mounting the transmission to the engine but as I don't want to leave the engine hanging on the crane or resting on the oil sump, I will need to make a frame so it can sit on the engine and transmission mounting points.
Cheers
Jim

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01 Mar 2021 20:04 - 01 Mar 2021 20:06 #270051 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The alternator connector has never had a cover and now also has this insulation problem.

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I was able to buy a cheap generic connector on ebay.

www.ebay.co.uk/itm/3-Pin-Universal-Alter...e:g:~VIAAOSwGPxaKl21

A new wire spliced in and the new connector fitted.

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I then started to weld up a frame to support the engine, it was going well...

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...... until the welder started to fail.

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It then completely died.

A quick poke around inside revealed nothing, so I left it for 10 minutes and it burst back into life, I think a thermal cut-out out had triggered.

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I'll finish the job tomorrow and move the engine off the stand and onto my new support.

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Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 01 Mar 2021 20:06 by Racediagnostics.
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01 Mar 2021 23:30 #270069 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi Jim,

I believe your welder wants a cleaning!
The dust makes cooling less effective and, depending on its character, could also have an impact on the connectors and/or the functionality of the PCB.

Regards,
Lutz
Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
Samuel Butler
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02 Mar 2021 20:32 - 02 Mar 2021 21:25 #270133 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The first job today was to flip the engine and fit the feet at the rear of the block.

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Next I removed the restored pan from the transmission and replaced it with the one from the old trans. I will refit the new one once it is back in the engine to avoid the paint being scratched.

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Transferring the engine from the stand to the crane. Lots of parts removed first, they will be refitted once the engine is back in the car.

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My dolly could do with being a bit wider, so I welded the two supports together.

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The block supported at the back with timber.

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Next the rear cover, treated with hylomar and grease packed into the seal to stop its internal spring from falling out when fitting.

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This part which is bolted to the intermediate cover seems to be there just to collect oil leaks from the rear of the engine.

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Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 02 Mar 2021 21:25 by Racediagnostics.
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02 Mar 2021 20:34 #270135 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Intermediate flange fitted.

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Finally the flex plate fitted.

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Ready for the transmission tomorrow.

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Cheers
Jim

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