Ultimate OM642 build (2009 R320L CDI, 7G-Tronic)

[ajlsl600]

be

If you decide to rebuild it, grind in the valve seats and fit new valve seals, it would be false economy not to while the heads are off.

berfore u do that pour some diesel in the intake ports and see if valves are leaking then do exhaust , give you a good idea of, if ,where valve seat issues are.

 

[Ge2tis]

be

berfore u do that pour some diesel in the intake ports and see if valves are leaking then do exhaust , give you a good idea of, if ,where valve seat issues are.

Did that...no leaks but quite a bit of soot everywhere, especially on intake valves..

 

[Ge2tis]

Update time...
So, yesterday was all about taking everything to bits... I took all the pistons out...then dismantled those..nothing seemed damaged except that most of the big end bearings had some markings (see pictures, shows very clearly). My brains comes to thinking that it was done by small metal bearing particles that were circulating when No.6 big end gave up.
As that was about everything that I could do with the block until I have that flywheel locking tool, I continued to take the heads apart...lifters and rocker arms put in the oil to keep them soaked. Then valves were taken out with a very decent Clarke tool (pictured), labelled and put in separate bags for when putting it all back together .I bought this spring compressor because I don't like the levered ones and this one made my life much easier. Recommended if you plan on doing something like that (disclaimer: I have no connections with Clarke or any tools manufacturer, just my opinion) .
Right...that's it so far...unless someone could lend me a very strong impact gun to undo the pulley bolt...
Pictures coming your way...

 

[Ge2tis]

More photos...

 

[Ge2tis]

More photos..

 

[Ge2tis]

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[Ge2tis]

More photos..

 

[Ge2tis]

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[Ge2tis]

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[Ge2tis]

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[LostKiwi]

That conrod in the top few pics will need replacing. The bearing has been spinning inside the rod and has damaged the rod.
Given that I would be tempted to get the rods balanced (the rod weights are equalised overall and end to end) before reassembly.
I'm also not sure that crankshaft will be reusable looking at the amount of damage.

 

[Ge2tis]

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[Ge2tis]

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[Ge2tis]

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[LostKiwi]

Incidentally - if you haven't marked how the caps go on the conrods then every rod will need replacing as the cap MUST go back on the same rod in the same orientation.

 

[Ge2tis]

Last set from yesterday...

 

[M80]

I'm gonna need a bigger hard drive.

 

[M80]

I think this is an interesting project and may become relevant to me, even if only in part.
With the time effort and money you're likely to put into this wouldn't it be a better option to pick up a pre owned engine?

Knowing the replacement is of good serviceable quality is the issue of course, you might end up with another duff 'en, even one that's been hydrolocked. But if the breaker can show a serious accident damaged vehicle that should reduce the risk.

 

[Ge2tis]

Incidentally - if you haven't marked how the caps go on the conrods then every rod will need replacing as the cap MUST go back on the same rod in the same orientation.

I did...every single one... however I am trying to find anyone that would have a set of new ones in stock or could make one..as mine do have 180k and might not be suitable for another 180k that I plan on putting on this engine..
I found one company in Germany that has OE for around £260 per set with postage...but I have my doubts...I much rather pay a bit more and have it sourced locally...I asked a dealer and their price is £199 each...not the kind of money I want to pay for that..

 

[Ge2tis]

I think this is an interesting project and may become relevant to me, even if only in part.
With the time effort and money you're likely to put into this wouldn't it be a better option to pick up a pre owned engine?

Knowing the replacement is of good serviceable quality is the issue of course, you might end up with another duff 'en, even one that's been hydrolocked. But if the breaker can show a serious accident damaged vehicle that should reduce the risk.

That's exactly my concern about buying a second hand engine from someone...I could end up with same problems anyway...I much rather spend a bit more and do it my way knowing what's been put inside...and looking after it as it should be done...