Engine swap checklist - Mercedes-Benz Forum
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post #1 of 26 (permalink) Old 03-16-2005, 09:59 PM Thread Starter
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Engine swap checklist

Please reply with anything I'm missing. Especially in the engine remove/replace area. The more eyes I put on the plans, teh better chance I have of it going smoothly.

Thanks!

-Dave G.

PREP ENGINE
Lash valves
Replace oil pan
Rebuild/replace vac pump?
Port head & manifolds
Replace head gasket?
New belts and hoses
Mount new WP pulley & fan
Heat shield above turbo
Water temp adapter bushing?
Plug gauge ports
Clean engine
Tap manifold for pyrometer
Adapters for oil temp/pres/light
Mounting brackets on engine
Flywheel/clutch assembled
Replace oil cooler lines
Clean up PCV lines
Powder-coat valve cover, intake, & air filter?

PREP for SYSTEMS
Obtain vac line for booster
Vac/pressure lines for engine controls
Plan Routing of battery cables, glow power + purchase wire, blocks, & terminals
Clutch verified/rebuilt
Flywheel balanced
Make fuel line adapters
1’ of 5/8� dia fuel line
AN adapter for 5/16 supply hose
3’ of 5/16� fuel line + clamps
obtain pipe for air filter adapt (size?)
Obtain exhaust components
Obtain battery & voltage cutoff
Mount idle adjust?
Mount gauges?

Day 1
REMOVE ENGINE

Disconnect battery
Disconnect wiring
Remove engine electrical components
Disconnect fuel lines
Cut vac line to booster
Disconnect throttle linkage
Disconnect PS lines
Disconnect heater lines
Disconnect exhaust
Disconnect clutch hydraulics
Disconnect trans linkage
remove & Inspect intermediate prop shaft
Remove radiator, winch, grille
Remove engine & trans mounting bolts
Lift engine out
Remove header pipe
Degrease chassis and engine bay

FIT NEW ENGINE
Replace rubber engine mounts
Transfer oil cooler to new engine
Mount transmission to new engine
Set engine in place
Bolt engine & trans to mounts

Day 2
Fabricate exhaust adapters
Connect heater lines
adapt air filter
Connect vac pump inlet to air filt.
Connect fuel lines
connect vac booster to check valve
connect throttle linkage
connect idle adjuster
Mount & wire glow relay
Mount, wire & plumb overpressure solenoid
Mount, wire & plumb vac shutdown solenoid
Connect alternator
Connect PS hoses
Replace trans linkage bushings
Connect trans linkage
Refit prop shaft
Reconnect clutch hydraulics
Bleed clutch hydraulics
Replace fuel pump and filter w. adapters
Mount radiator
Mount oil cooler
Fill fluids
Test fire
Check system for leaks
drain fuel
Fill fuel tank
Refit grille & winch
Wire (& mount?) gauges
Mount, wire & plumb turbo defeat solenoid
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post #2 of 26 (permalink) Old 03-16-2005, 11:51 PM
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RE: Engine swap checklist

Very thorough: but there is one thing that you might like to consider with such an impressive project. A good supply of cold beer at the end of the day – just a thought. [}:)]

Good Luck!
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post #3 of 26 (permalink) Old 03-17-2005, 04:14 AM
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RE: Engine swap checklist

Hi Dave
I can't add anything to your list seems pretty good.
Have you thought about a turbo service? New bearings and seals.

Good luck with it. When is D-day?
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post #4 of 26 (permalink) Old 03-17-2005, 05:11 AM
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RE: Engine swap checklist

Quote:
Roly - 3/17/2005 7:14 AM
Good luck with it. When is D-day?
D-day, that would be DIESEL-day in this case, wouldn't it?[:D]

www.g-wagen.no
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post #5 of 26 (permalink) Old 03-17-2005, 07:54 AM Thread Starter
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RE: Engine swap checklist

From that picture, it looks like the frosty mornings turn the whole G into a giant beer cooler. Oh wait, you folks perfer it warm...[8D]

-Dave G.
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post #6 of 26 (permalink) Old 03-17-2005, 08:04 AM Thread Starter
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Turbo Service

I did indeed consider it. Especially since mine shows some signs of leaking a bit of oil - no drips, just a little surface dampness.

I wonder if it's better to get the dealer parts, or go to a Garret source. I have a buddy who works in the foundry at Garret Air Research in California....Sounds like a fun place, or maybe it's just this guy....I digress.

Yep. I think you're right. Maybe a good time to consider a turbo service.

Might even be the right thing to take it to some kind of expert who could verify balance, etc. Might be more to it than a water pump, is all I'm thinking.

The motor has 130k miles and ran well before we pulled it from the '79 300SD it was in.

Comments?

-Dave G.
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post #7 of 26 (permalink) Old 03-17-2005, 09:02 AM
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RE: Engine swap checklist

Our turbo has 330,000 miles on it and is going strong. Never touched. Yours has broken in by now. They are easy to R+R if there is a future issue.
Also consider having the exhaust manifold ceramic coated.
I like Conti belts or Gates Green stripes.
The valve cover and intake manifold are alloy and could be annodized.
Replace all of the little injection return line hoses that loop from injector to injector.
Modify the alternator for a tach trigger.
-Dai
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post #8 of 26 (permalink) Old 03-17-2005, 01:21 PM Thread Starter
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Thanks Dai

Good thoughts on the ceramic coating for the exhaust manifold. My idea with PC on the intake and valve cover was to create a nice smooth surface that's easier to wipe clean than the porous aluminum.

replacing return lines is a good one I hadn't thought of. I'm not sure about the alternator. I haven't looked into whether or not the one currently on the M110 and the one from the car are similar enough that I can keep one for a spare. If they are I'll do that and maybe get the alternator modified for the tach tap.

But there are a lot of different ways to go for a diesel tach so I'll probably wait and cross that bridge when I come to it. Heck, I might even see what I could do about beefing up the stock diagnostic cap circuitry. Who knows.

Thanks for the input. Let me know if you think of anything else.

-Dave G.
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post #9 of 26 (permalink) Old 03-17-2005, 08:52 PM
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RE: Thanks Dai

Hey Dave,
I'm excited about watching your project unfold. I'm assuming you're going to document everything for a great conversion article for the clubgwagen site. What did you decide to do about AC and/or onboard air? If I remember correctly, you have a trick set up with a York compressor. You probably know this but.....if you plan on using your York with the new engine, and if you use the super abundant AC bracket that was made especially for your York on the SD motor, it will end up in the way of the turbo goose neck. On mine, Norm had his mechanic use a modified York bracket and a Sanyo compressor, slightly elevated, in order to make room for the turbo. Then, the mechanic slapped on an ABS 45 degree elbow and a K&N filter for air intake. The goose neck had to be rotated (looking at the engine from the front) 90 degrees counter clockwise. I tossed the K&N and put the stock air cleaner back in. It works great and looks pretty darn good if I do say so myself. If you want me to take pics, let me know. I'm sending the air cleaner housing off to get powder coated next week and should have everything back together soon.
Good luck...can't wait to see the progress. The diesel is a little bit of a dog, but I suspect you're heading towards free/green fuel. You'll love it.
Here's a pic of my latest interest.....my boy Jack, 10 pounds, 6 ounces....born on 2/27.
Steve
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1982 300GD Turbo
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post #10 of 26 (permalink) Old 03-17-2005, 09:58 PM Thread Starter
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Congratulations!

Really introduces some perspective, doesn't it! Glad everybody's happy and healthy. Is this your first? Man there's nothing like it, that experence of being part of a new life coming into existance, and it only gets better and better every day. I wouldn't trade our 3 for anything.

I would like very much to see a picture of the pipe you have going to the stock air cleaner. That's something I'll have to do, but can't do until the motor's in, so the more info I can have about how that arrangement MIGHT go, the better job I can do of at least having the right materials on hand when it comes time to fab.

Right now I'm somewhat up against it with the clutch/flywheel situation and I might have to introduce some dead time into the project to get my 280 flywheel re-faced in the middle of the swap.

See my other post on flywheel.

I just can't get over your fantastic news about the new little tyke...love 'em till it hurts man.

[:)]

All the best,

-Dave
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