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

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24 Mar 2021 09:38 #272005 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
I knew that I have seen that clip but I didn't remember where.
Frank is right, the heat shield under the battery is kept in place with this clip at one side and a screw at the other side.

Regards,
Lutz
Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
Samuel Butler

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24 Mar 2021 09:51 #272008 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I am confused, I have never seen a heat shield there. But it would make sense to protect the brake line from the exhaust manifold. Does anyone have a picture.
Cheers
Jim

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24 Mar 2021 10:34 #272014 by Sternenkreuzer
Replied by Sternenkreuzer on topic Engine rebuild with no former experience........
Hi Jim,
i found a photo....
It is directly under the battery, one screw M6 an this clip.
The photo is not very clear.
 
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Grüße aus Hamburg.

Frank
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24 Mar 2021 10:37 #272016 by Sternenkreuzer
Replied by Sternenkreuzer on topic Engine rebuild with no former experience........
next picture...
The Shield itself clip location is marked.

 
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Grüße aus Hamburg.

Frank

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24 Mar 2021 10:37 #272015 by Sternenkreuzer
Replied by Sternenkreuzer on topic Engine rebuild with no former experience........
next picture...
The Shield itself clip location is marked.

 
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Grüße aus Hamburg.

Frank
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24 Mar 2021 11:58 #272024 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
RHD cars might not have that heat shield, for whatever reason. But you still have the clip .....

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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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24 Mar 2021 13:54 #272037 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Thanks for the pictures Frank, however I think Lutz is correct. EPC says the heat shield is not fitted on my (RHD) car. Looks like it must have been planned at one point but never implemented.
Cheers
Jim

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24 Mar 2021 14:06 #272038 by Sternenkreuzer
Replied by Sternenkreuzer on topic Engine rebuild with no former experience........
Hi,
so still missing the position of the clip :-)
Grüße aus Hamburg.

Frank

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24 Mar 2021 21:37 - 24 Mar 2021 21:38 #272088 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Mundane activities today.

Subframe bolted in.

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Brake pipes connected up.

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Anti roll bar bolted on.

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Drop links on too.

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Bled the brakes.

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Engine mounts fitted.

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Washed the wheels.

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Then the wheel arches.

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Shock absorber top nuts fitted, I'm not sure how tight these should be, need to check the workshop manual.

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Finally the steering links bolted back together.

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That's the car now safe to roll around.
Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 24 Mar 2021 21:38 by Racediagnostics.
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25 Mar 2021 08:45 #272109 by PanTau
Replied by PanTau on topic Engine rebuild with no former experience........
Hello Jim, 
The upper washers of the shock absorbers must be fitted the other way arond.

Best regards
Frank
 
VG
Frank
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25 Mar 2021 09:18 #272113 by wusel-53
Replied by wusel-53 on topic Engine rebuild with no former experience........

Hello Jim, 
The upper washers of the shock absorbers must be fitted the other way arond.

Best regards
Frank

 
And the screws must be screwed in all the way. There is no torque specification here.
Viele Grüße

Thorsten

Man lernt nie aus
380SL (US-Version, Bj.84), Eura-Wohnmobil und ein ebike :-)
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25 Mar 2021 09:28 #272115 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Thanks for the advice guys.
Cheers
Jim

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25 Mar 2021 21:36 - 25 Mar 2021 22:27 #272204 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Big day today!

Car pushed out of the garage so I could move the car lift.

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Car lift out of the way, the best tool I ever bought.

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Lifting the engine.

www.youtube.com/watch?v=6qhOzdbQAlE

Here we go....

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The starter motor was fouling on the engine mount, This happened last time I put the engine in so I removed the mount till the engine was in a bit further.

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Engine on its mounts.

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Prop shaft connected and then the trans mount and support fitted.

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That's it in and self supporting. It will take a few more days to get all the ancillaries, fuel injection, exhaust etc installed. Then the first trial start.

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Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 25 Mar 2021 22:27 by Racediagnostics.
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25 Mar 2021 22:53 #272215 by KaiDase
Replied by KaiDase on topic Engine rebuild with no former experience........
Congratulations, what a big day!

I’ve been keenly following your work, what a pleasure to see (especially since you have “no former experience”).

Looking forward as always to your updates.

Best wishes,
Kai
Mercedes R350, 11/2006
Cherokee 2.5, 04/2000
Hyundai H1 4x4 07/1999
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25 Mar 2021 22:58 #272216 by Dr-DJet
Replied by Dr-DJet on topic Engine rebuild with no former experience........
Hi Kai,

Jim is a physicist and for physicists Problems are to be solved!

Congrats to your car's marriage Jim! We keep our fingers crossed for a smooth engine start.

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Viele Schraubergrüße - best regards, Volker, Admin und Betreiber dieser Webseite
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26 Mar 2021 09:40 #272238 by wusel-53
Replied by wusel-53 on topic Engine rebuild with no former experience........
Don't forget the oil 

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You're doing a great job. I'm a I am a huge fan of your report.
Viele Grüße

Thorsten

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

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30 Mar 2021 21:03 - 30 Mar 2021 21:06 #272534 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Back into the garage after a four day break

Alternator fitted.

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Harmonic balancer and pulley.

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Power steering pump.

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This PS hose union is tricky to tighten, I used a 3/8th inch crows foot and my serpentine belt tensioner tool.

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Engine mount heat shield and engine suspension lever.

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Exhaust manifold.

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Engine shock absorber fitted, look closely at the bottom washer under the lower rubber.

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It was still stuck to the rubber when I dug it out and missed all the de-rusting and plating. They are still available new so I will buy a couple (its the same on the other side) as I don't want to get all the plating equipment out again just for these.

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Spark plug cable heat shield fitted.

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Fuel system fitted.

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Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 30 Mar 2021 21:06 by Racediagnostics.
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30 Mar 2021 21:04 - 30 Mar 2021 21:07 #272535 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Aaaarrrghhh!!!!

The throttle body rubber boot clamp wont tighten, something is wrong with the way its configured. I will need to remove the fuel system to get it out and fix it.

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It looked like this when I removed it.

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Cheers
Jim

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1979 450SL - 2002 XK8 4.2
Last edit: 30 Mar 2021 21:07 by Racediagnostics.

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30 Mar 2021 22:27 #272537 by mike 560
Replied by mike 560 on topic Engine rebuild with no former experience........
Hallo Jim

it looks great,perfect work.i make a big poster from the engine,and hang it in my garage.

Mike
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30 Mar 2021 22:31 #272539 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi JIm,

how does it feel now when the first start after the rebuild is getting really close?

Regards,
Lutz
Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
Samuel Butler

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31 Mar 2021 00:44 #272541 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Great, I'm looking forward to the first drive but worried about the first engine start.

It looks like the hose clamp above is no longer available, does anyone know what this "side/edge tightening" clamp is called?

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Cheers
Jim

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31 Mar 2021 08:13 #272543 by Sternenkreuzer
Replied by Sternenkreuzer on topic Engine rebuild with no former experience........
Hi Jim,

i think you can just use the newer one, this is from MOPF-V8....

 
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Grüße aus Hamburg.

Frank
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31 Mar 2021 08:14 #272544 by Sternenkreuzer
Replied by Sternenkreuzer on topic Engine rebuild with no former experience........
Me again,
and just get 2 of the Binders...
Its a mess mounting them, my personal opinion....
Grüße aus Hamburg.

Frank

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31 Mar 2021 20:12 #272578 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Thanks Frank, I managed to reassemble the existing clamp, see below.

Fuel system off again to get access to the clamp.

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The band had sheared off in the slot of the tightening screw.

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I was able to pick it out.

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Refitted and tightened.

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Next I fitted the fuel pipe clips, 4 in these positions, did I miss any?

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Still have a few spares.

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Cheers
Jim

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31 Mar 2021 20:13 #272579 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Power steering fluid cooler fitted.

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New hoses fitted.

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Next the throttle linkage, there seemed to be too many parts in the bag.

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Fitted, I'm sure the large washer with rubber bonded should be used somewhere.

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Next I filled the PS system.......

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.....and spun it up with a drill to bleed all the air out.

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Last I jacked up the front of the car and tested out the setting I'd put into the steering box, it ended up with about 10mm of free play at the steering wheel.

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With that set I could move onto the exhaust manifold.

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Surprisingly I was able to get this torque wrench onto all the nuts and bolts, but I have no idea what torque they should be set at, does anyone know?

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Cheers
Jim

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31 Mar 2021 23:42 #272589 by Dr-DJet
Replied by Dr-DJet on topic Engine rebuild with no former experience........
Hi Jim,

regarding torque have a look at 49-100 in our SLpedia .
Viele Schraubergrüße - best regards, Volker, Admin und Betreiber dieser Webseite
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01 Apr 2021 00:58 #272592 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Volker,

I had a look but it only discusses the "exhaust to manifold" nuts and bolts but not the "manifold to head" torque.

Online resources suggest 17Nm for M8 steel bolts in to aluminium vs ~25Nm for steel bolts into steel.
Cheers
Jim

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01 Apr 2021 17:13 #272614 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Yes, I looked into the WIS after Jim's post from yesterday for different models and in different chapters where the exhaust manifold was removed and nowhere a manifold-to-head torque was mentioned.

Regards,
Lutz
Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
Samuel Butler
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01 Apr 2021 18:25 #272617 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I had a look in my XK8 repair manual which stated 25Nm but online resources say 17Nm for Aluminium, in the end I set both sides to 19Nm, I can always tighten them up a bit if they blow.

Right side engine shock etc fitted.

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Cross brace and fly catcher fitted.

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Radiator fitted.

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Power steering cooler flex hoses and horns fitted, don't flame me about the non genuine horns, I'll buy better ones sometime.

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I then spent an hour searching for the coolant bottle before finding it in the boot!

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Cheers
Jim

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01 Apr 2021 18:44 #272619 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Here is an interesting comparison, the pic below is from 20th March 2011 when I put this engine in the car.....



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....and one from 30th March ten years later in a similar state of assembly.



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Cheers
Jim

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