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

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30 Nov 2020 16:21 #263772 by Obelix116
Replied by Obelix116 on topic Engine rebuild with no former experience........
...na sowas !

Gruß
Christian

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30 Nov 2020 16:30 #263776 by wusel-53
Hi Jim,

I hope the whole thing will still appear as a workshop article in compressed form. Great job description. Keep it up!

I hope my english is not too funny :silly:

Viele Grüße

Thorsten

Man lernt nie aus
380SL (US-Version, Bj.84), Eura-Wohnmobil und ein ebike :-)

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30 Nov 2020 17:57 #263789 by Sternenkreuzer
Replied by Sternenkreuzer on topic Engine rebuild with no former experience........
Hi,

i had a look for another dip-stick tube which would fit maybe....
Really shocking nearly 165 € and not available.

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Grüße aus Hamburg.

Frank

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30 Nov 2020 19:04 #263794 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Richard, thanks for trying anyway, I will zinc plate the old one.

Cheers
Jim

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30 Nov 2020 22:00 #263807 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Someone suggested to use oven cleaner to tidy up the lower intake manifold, it didn't really work very well.

Potassium Hydroxide + pitted Aluminium => Hydrogen + "soot that is not easy to remove"

Perhaps they were thinking about a different recipe for oven cleaner or smooth aluminium.

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After wire brushing and power washing, marginally better than what I started with.

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I needed a wire brush for cleaning/polishing parts so .....

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The used CAM bearings from ebay also arrived, they are in perfect condition.

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Cheers
Jim

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30 Nov 2020 22:15 - 30 Nov 2020 22:36 #263808 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Taking a closer look at the valve guides. The intake guides have plenty metal to drive them safely into the head from the top end, however the exhaust valves look very delicate at the top edge which will take the driving load.

Here is a pc of both intake and exhaust guides from the top and below, plenty meat on the bottom of both.

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I'm thinking about removing the snap rings and driving the exhaust guides in from below. Either way I will heat the heads to 80degC and buy some dry ice to cool the guides and drive in tools down to -80degC.

The original MB "drive in" tool (110589011500) looks like this. Looking at it's shape it would seem to me that the drive in pressure must be applied to the top edge rather than some lower part of the guide. Hence the need to ream the guides after use.

Has anyone ever seen or used one of these? I've also seen it listed as 910589011500.

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Cheers
Jim

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Last edit: 30 Nov 2020 22:36 by Racediagnostics.

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30 Nov 2020 23:49 #263811 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I worked out that the CSA of the top edge is about 30sqmm and that the snap ring shoulder is 50sqmm so I'll make a tool to push down on the snap ring shoulder from the top then replace the snap ring..

Cheers
Jim

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01 Dec 2020 18:27 #263840 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
This morning I made up two new tools to push in the inlet and exhaust valve guides.

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The tool pushes on the shoulder of the intake guide and one the snap ring locator on the exhaust guide.

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Chased out the spark plug threads.

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Then cleaned up the starter motor.....

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....and got them primed.

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Cheers
Jim

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02 Dec 2020 12:19 #263886 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I paid for 1 hour of vapour blasting on these parts. Not perfect but more than good enough.

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Cheers
Jim

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02 Dec 2020 13:09 #263895 by Marcel
Moin Jim,

great job

Gruß Marcel
300 CE-24 Bj 7/90

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02 Dec 2020 17:48 - 02 Dec 2020 17:49 #263914 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I painted the solenoid and starter motor today.

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Then on to fix this rusted and sheared off bolt.

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I drilled it out before getting the manifold cleaned but managed to damage the thread.

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So drilled it out and taped it for a helicoil.

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Installed with thread lock a bit below the surface so as to be fitted in good threads.

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Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 02 Dec 2020 17:49 by Racediagnostics.
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03 Dec 2020 18:56 - 03 Dec 2020 18:58 #264013 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I stripped the paint and rust off the harmonic balancer and main pulley today....

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....but spraying primer at 1 degC didn't work out too well. I will need to sand out the runs.

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Cheers
Jim

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Last edit: 03 Dec 2020 18:58 by Racediagnostics.

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04 Dec 2020 12:53 #264032 by PanTau
Hello Jim,

to assemble the pulley: It is easy to overlook the fact that one of the six screws is on a different locking circle, which defines the installation position. I didn't notice and wondered why I couldn't fit the last screw.

Best Regards

Frank

VG
Frank
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04 Dec 2020 18:07 #264039 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Frank, whoever changed the front seal in the past on this car did not know this, there were only 5 screws in the pulley! They obviously could get the last one in so just didn't bother.

Cheers
Jim

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04 Dec 2020 19:11 - 04 Dec 2020 19:20 #264042 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
First sleet of the year overnight.

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The delivery of dry ice turned up by 10.30. Somewhere below ~-80degC I presume, the digital thermometer only goes down to -50degC.

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Head in hot water, heating to 80degC and a couple of heater strips to keep the head hot once on the bench.

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Guides into chill.

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Head up to temperature.

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All the guides pushed in, all went in easily apart from two that took a bit more force.

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Next, two expensive reamers, 8.99mm and 10.99mm.

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They went through the cooled down guides fairly easily and only one seemed to cut a tiny amount.

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Lubricated with wd40.

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The next job will be to check the valve to seat seal.

Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 04 Dec 2020 19:20 by Racediagnostics.
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04 Dec 2020 22:31 #264050 by Chromix
Cool job ..... ;)

Hälsningar,
Lutz

Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
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05 Dec 2020 18:30 - 05 Dec 2020 18:30 #264088 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Ha ha, I still have 13kg of dry ice slowly evaporating in the garage, I only needed 1kg or so but the minimum order was 15kg.

Today was spent lapping the valves. First engineers blue on the seats....

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...and valves.

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I used course then fine lapping compound using a conventional hand tool.

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It was a slow pita but it showed all valves to be concentric with the seats, all valves showed a very consistent even pattern.

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I then gave all the valves a second lap with the fine compound again using Martin's method. Using the hose to connect the drill takes out the risk of canting the valve stem.

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Finally I did a leak test, each recess filled with water.

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I ended up with a small single drip on about half the valves after 5 minutes. I have no idea if this is good enough or not, I guess with the valve springs fitted this would be much better.

Tomorrow the other head.

Cheers
Jim

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Last edit: 05 Dec 2020 18:30 by Racediagnostics.
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06 Dec 2020 20:32 - 06 Dec 2020 20:34 #264209 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Today I put the springs back on the first head to try a leak test with them.

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Then filled the runners with brake cleaner.

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There was only just the tiniest of weeps from a couple of valves, to be honest, I am almost ready to call that good.

I will take the heads up the the bike engine builder (who did the TIG welding for me) tomorrow to get his opinion if the seal is good enough. There is nothing like getting an experienced pair of hands on the head, so I put both to one side for the rest of the day.

Next I went on to rebuilding the pistons, only lost one of the wrist pin retainers pinging across the garage.

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New, bearings fitted.

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Tried out the new torque gauge.

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Checked the dimensions, all was good.

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Then repeated for the other 8 pistons.

Cheers
Jim

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Last edit: 06 Dec 2020 20:34 by Racediagnostics.
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06 Dec 2020 21:53 #264215 by Marcel
Hi Jim,

Chapeau, you are doing a great Job.

Gruß Marcel
300 CE-24 Bj 7/90

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06 Dec 2020 23:31 #264225 by Dieseldok
Replied by Dieseldok on topic Engine rebuild with no former experience........
Hello,

did you got a brake bleeding vacuum bottle?
Valve test with vacuum shows much better if the seat is sealing or not.
You need just a plug or a flat iron/ alloy piece and plug the related channel.

Then you see which seat are good to go which one need more grinding work.

Nevertheless the valve and seats should seal good after the cutting job even before final grinding.

Kind regards

JP

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07 Dec 2020 20:40 #264298 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Today I finished lapping the second head, quite a time consuming job.

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I then took them up to the motorbike engine builder, very local, only 5 minuets away. He tested them with petrol in the intake runners and exhaust ports, the were a couple of ports with a very tiny slow weep. He said he would not do any further work on them and would be more than happy. He was amazed that the new guides had gone in so well and maintained concentricity. He had expected that the seats would have had to be re-cut, the workshop had a full set of Nuway cutters but he advised not to do it.

He had a very interesting workshop, and was rebuilding a racing engine with titanium valves......

Next I plan to go through the 80 or so plastic bags with parts in them and remove, clean and catalogue all the nuts and bolts and decide which to replace, re-plate or reuse.

Cheers
Jim

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08 Dec 2020 20:55 - 08 Dec 2020 20:56 #264371 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Kim getting ready to do some cataloguing.

[img]hhttps://www.racediagnostics.com/gallery/_data/i/upload/2020/12/08/20201208194900-e70e7edd-la.jpg[/img]

This pile will probably be scrapped, may change my mind when I find out the replacement cost.

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Parts to be plated.

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Parts to be cleaned.

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Now for a bit of excel and to check prices here.

www.belmetric.com/88-yellow-zinc-plated-...u9tjr71q50dt072v8f83

Cheers
Jim

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Last edit: 08 Dec 2020 20:56 by Racediagnostics.

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08 Dec 2020 21:01 #264372 by Rudiger
Jim, Clean it in Kerosin, bag it and store it away under your work bench.
Rudiger
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09 Dec 2020 15:38 #264392 by Gullydeckel
Replied by Gullydeckel on topic Engine rebuild with no former experience........
Hi Jim,

don't send the cylinder head bolts for plating! They are Nickel coated for low friction coefficient!
Otherwise you have a risk of damage the treads in the crankcase.

Regrads Martin

Ich bin jetzt in dem Alter wo ich meine Fehler zugeben könnte - wenn ich welche hätte
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09 Dec 2020 18:28 - 09 Dec 2020 18:31 #264406 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Martin, yes, all the head bolts have been separated, I will just clean the heads of the external ones and put on some cold bluing.

Well that's most of the hardware ordered from Belmetric in nice yellow passivated zinc, I will re-plate/reuse the M12 nuts and bolts. Trying to plate over 400 items myself would have just taken too long. The cost came in at about £95 for 422 items, however shipping is £40, then import tax will be the final sting in the tail.

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Cheers
Jim

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Last edit: 09 Dec 2020 18:31 by Racediagnostics.
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09 Dec 2020 19:04 #264409 by Moerten
Impressing work and documentation, Jim. Thanks for that. I have neither the space nor the tools (perhaps some skills...) but I enjoy following all your steps and the progress. I am keen to see it running again and the smile on your face when done.

Thumbs up.

Gruß
Martin
_____________________________________
Lass mich, ich kann das... Oh, kaputt.
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09 Dec 2020 19:42 #264420 by Chromix
Hi Jim,

I wondered why you mentioned import taxes, checked out Belmetric and saw that they are located in the US. Good grief, you are buying nuts and bolts in the US!!! And even metric ones!! :woohoo:
You could have found them here. I didn't check out all sizes but a few and they were available and they sell them by the piece.
Probably too late for you but maybe interesting for others as well.

Regards,
Lutz

Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
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09 Dec 2020 20:58 - 09 Dec 2020 21:00 #264424 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Lutz, thanks for the link, I will use them for future orders. I had a quick look at the prices, they were ~20% higher than the US supplier, however they may end up being cheaper when import tax and shipping is taken into consideration. Definitely cheaper for small orders.

I had searched for a one stop shop in the UK but had not found a good supplier for yellow passivated zinc.

Looking on the positive side, I saved a fortune by not buying from MB.

Cheers
Jim

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Last edit: 09 Dec 2020 21:00 by Racediagnostics.

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09 Dec 2020 21:53 #264429 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Is there anything I need to take care with when I remove the Fuel Distributer from the part below?

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Cheers
Jim

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10 Dec 2020 09:26 #264437 by Gullydeckel
Replied by Gullydeckel on topic Engine rebuild with no former experience........
Hi Jim,

no, nothing special.
You should renew the rubber fuel lines, the material is available for little money:
sternzeit-107.de/de/forum/forum-107/1730...orraum-zum-verteiler
As well you will need to exchange the lower (rubber) part of the Fueldistributor/air vane housing.

Be careful with the small plastic brackets at the fuel lines, they are not longer available, but you can 3D-Print them:
sternzeit-107.de/de/forum/forum-107/2028...ritzleitungen#203684
The STL-file now is located in the download-section.

Regards Martin

Ich bin jetzt in dem Alter wo ich meine Fehler zugeben könnte - wenn ich welche hätte
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