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S-Class (W140) 1991-1999: 300 SD, S 350TD, 300 SE 2.8, S280, 300 SE 3.2, 300 SEL 3.2, S320, S320L, 400 SE, S420, 400 SEL, S420L, 500 SE, S500, 500 SEL, S500L, 600 SE, S600, 600 SEL, S600L, 500 SEC, 600 SEC

1992 W140 300SD Rebuild

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Old Aug 20, 2019 | 02:04 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
1992 W140 300SD Rebuild
Some time ago i purchased W140 300SD off eBay. In spite of seller promises car came in not so good mechanical conditions so as a MB fan i decided to did complete rebuild on. Just want to show you progress done on it

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Old Aug 20, 2019 | 02:06 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Engine out
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Old Aug 20, 2019 | 02:09 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Cylinder head overall ok. Carbon buildup. A dent in 6th cylinder sealing surface - from someone working on engine before.
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Old Aug 20, 2019 | 02:11 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Crankshaft - some deep scratches, beyond polishing out
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Old Aug 20, 2019 | 02:14 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Cleaning aluminum components. I used Simple Green Extreme Aircraft and Precision Cleaner. Soaking in 1:1 diluted for couple days. No etching or aluminum damage.
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Old Aug 20, 2019 | 02:17 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Cylinder head resurfaced in machine shop. Didn't like conditions of valves, replaced with fresh set of new ones.


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Old Aug 20, 2019 | 02:21 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Engine block had minimum wear. Ended up honing cylinder surface with Flex Hone and painting block in yellow.


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Old Aug 20, 2019 | 02:25 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Grinded crankshaft to first repair oversize +0.25. Overall grind work clearance within factory specs.




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Old Aug 20, 2019 | 02:31 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Had all six bended connecting rods and damaged pistons.
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Old Aug 20, 2019 | 02:33 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Replaced connecting rods with newer version and purchased new set of pistons. Had to do some machining on pistons to fit newer thicker connecting rods.




Last edited by arsupisemnet; Aug 20, 2019 at 02:36 PM.
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Old Aug 20, 2019 | 02:34 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Installed new timing chain kit
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Old Aug 20, 2019 | 02:35 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Engine block ready to be installed back in a car

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Old Aug 20, 2019 | 02:47 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Complete rebuild of transmission. Installed transmission valve kit for diesels. Not noticeable shift between 1 and 2. Put new brake bands. Replaced brake band piston with automatic adjuster from newer model.





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Old Aug 20, 2019 | 02:49 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible



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Old Aug 20, 2019 | 02:51 PM
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From: New Orleans
2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Complete rebuild of both engine harnesses




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Old Aug 20, 2019 | 02:53 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Engine back in the car. Replaced oil thermostat and oil cooler.




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Old Aug 20, 2019 | 02:56 PM
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2014 GL450, 1992 W140 300SD, 1993 W140 300SE, 1987 E30 Convertible
Engine running. Next step planned as follow:
1) Install electric fuel lift pump.
2) Install larger turbo (i have stock one, which i rebuilded as well)
3) Install larger plungers into inline fuel pump.
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Old Jan 18, 2022 | 12:05 PM
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impressive work!
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