Coupe to road

1976-1985: 230T, 230E, 230TE, 230CE, 280E, 280TE, 280CE, 240D, 300D, 300CD, 300TD,
mathuisella
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Re: Coupe to road

Post by mathuisella » Thu 11 Oct, 2018 7:01 pm

So, still having issues with this lumpy idle.

So far.

Valve adjustment
new injectors @ 145 BAR
injection pump valves removed, cleaned and put back in.
new filters + fuel


Engine mounts are next on the list. Kinda running out of things to check haha.

https://youtu.be/hCGojkm_QnA

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Tony From West Oz
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Re: Coupe to road

Post by Tony From West Oz » Thu 11 Oct, 2018 11:30 pm

Did you notice the wear on the cam follower on one valve (around the middle of the cam) was offset - wearing on one side of the cam follower.
I did mention this as the most likely cause of the lumpy idle when warm and included spare parts to overcome this issue.
Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (SOLD)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

mathuisella
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Location: Brisbane, North side.

Re: Coupe to road

Post by mathuisella » Thu 11 Oct, 2018 11:54 pm

Tony From West Oz wrote:
Thu 11 Oct, 2018 11:30 pm
Did you notice the wear on the cam follower on one valve (around the middle of the cam) was offset - wearing on one side of the cam follower.
I did mention this as the most likely cause of the lumpy idle when warm and included spare parts to overcome this issue.
Tony
I saw some wear on a cam lobe, but didn't think it was in the contact area.

I'll take another look with the valve cover off tomorrow :)

Cheers for the reply.

I'll take some good pictures.

mathuisella
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Re: Coupe to road

Post by mathuisella » Mon 15 Oct, 2018 8:04 pm

Evening all, sorry about the delay in reply with an update, it's been raining so much here i've not had much of a chance for car work.

So Tony suggested looking at the rockers.
20181015_141228 - Copy.jpg
hmm, just now starting to take a look.

It seems the sleeves have been damaged.
20181015_141416 - Copy.jpg
closer examination
20181015_162944.jpg
after filing the excess off, it was time to mock up reinstallation and see what's happening.

So, it seems the rod doesn't have the notch cutout in the right spot for the locking down bolt to pass through and keep it all together and in place...
20181015_171507.jpg
So, rather than trying to wedge it all together, which is possibly the cause of the rough idle due to excess stress on the rocker arms, i decided to cut out the excess material.

Using a hand angle grinder with a sanding disc, i got this as a result, not too bad i think considering by hand with no guides in the shed.
20181015_172530.jpg
after doing this, i went and mocked it all up again.

Perfect :)

So i'll be putting it all together again tomorrow morning.

Also to do, run a small wire through the Fuel hardlines between the injection pump to injectors, as per how things were gummed up before, i'm pretty sure the passageways need a good cleaning out as well.
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Tony From West Oz
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Re: Coupe to road

Post by Tony From West Oz » Mon 15 Oct, 2018 9:53 pm

Hmmmm so it was that way since the engine overhaul.
Was the rod symmetrical, or is there an offset at one end of it causing the offset of the bolt hole at one end?
Was the rod bent at all?, I originally felt that this may have been the cause of the unusual wear on the rocker.
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (SOLD)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

mathuisella
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Re: Coupe to road

Post by mathuisella » Tue 16 Oct, 2018 6:53 pm

it's strange, the parts were forced together to hard, i do wonder if the rocker towers were straight.

the 2 rods looked to be within 0.5mm of each other in terms of straightness, i held them up to one another against the light and they both seemed perfectly straight, i would just say how things were forced together may have caused things not to run so well.

i do hope the other rocker towers are good.....

rain again so no car stuff today.

mathuisella
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Re: Coupe to road

Post by mathuisella » Tue 16 Oct, 2018 7:46 pm

Tony From West Oz wrote:
Mon 15 Oct, 2018 9:53 pm
Hmmmm so it was that way since the engine overhaul.
Was the rod symmetrical, or is there an offset at one end of it causing the offset of the bolt hole at one end?
Was the rod bent at all?, I originally felt that this may have been the cause of the unusual wear on the rocker.
has the lumpy idle been there since day 1 of engine overhaul ?>

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Tony From West Oz
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Re: Coupe to road

Post by Tony From West Oz » Tue 16 Oct, 2018 11:30 pm

I cannot recall that far back.
Something to do with getting older.
I meant to put a ? at the end of that sentence:
Hmmmm so it was that way since the engine overhaul?
All you can do is to check it out when you put it back together again.
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (SOLD)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

mathuisella
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Joined: Sun 08 Jun, 2014 6:03 am
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Location: Brisbane, North side.

Re: Coupe to road

Post by mathuisella » Thu 18 Oct, 2018 7:06 pm

It looks like that may have been it, the lumpy idle is better, but not as good as the red 300d. So next is the engine mounts.

mathuisella
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Re: Coupe to road

Post by mathuisella » Fri 19 Oct, 2018 7:56 pm

well, yet to complete the engine mount change as the sun disappeared on me this evening.

but here's what i've got so far.

taking the bolts out, these ones were from under the turbocharger side/ drivers side, not a good sign...
44310956_1896759897081626_5089121755646132224_n.jpg
and the mount itself
44313060_1752884318172155_4804234423123836928_n.jpg
the left side/fuel side wasn't that much better either, however, when compared to the new mounts, wow did one of them get compressed over time...
44234921_249060025766397_7414169595159773184_n.jpg

now in the midst of putting the new mounts in after cleaning the areas and giving the shields a splash of paint to make it easier to see when oil starts to drip in the future.

44250846_249730182378239_3690641487369863168_n.jpg

and after
44273282_248476449149325_6366446326556655616_n.jpg
and now i've run out of sunlight.

so until next time. :)
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mathuisella
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Re: Coupe to road

Post by mathuisella » Sun 21 Oct, 2018 5:44 pm

https://youtu.be/nWrJDjCFm9U



after all the following, the engine has lost 99% of it's rough idle, yet to confirm 100% as i'd need to take it for a drive :P


1. fuel injector delivery valves.
2. fuel injectors nozzles.
3. engine mounts.
4. valve adjustment.
5. rocker arm correction.

Just need to find the source of this weird tapping noise, then we're all set to reassemble everything and work on less important things like the sunroof cable ect:

mathuisella
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Re: Coupe to road

Post by mathuisella » Fri 02 Nov, 2018 6:37 pm

Mounted the new radiators overflow container
20181031_170345.jpg

The mechanics stethoscope came in the mail today.

listening to different places, it seems i was right in there being a bit of an odd noise.

I think i need to adjust the valves on cylinders 4 and 5 again.




Sorry i forgot to grab a picture before i started clearing the leaved and junk out of the drainage section under the bonnet hinges.
this is partially cleaned...
20181031_150549.jpg

at the end, you can see where the metal has rusted through. I'll be fixing that up asap.
20181031_150908.jpg
Made this quick video to help others out as well who are new to w123's or chasing water....

https://www.youtube.com/watch?v=A7IjUAPqHW4



So...

getting things together

fibreglass, sacrificial paint brushes, scissors, prep stuff
20181102_154730.jpg
using the technique from this video
https://youtu.be/0UKPNaBAKFs



so sanding, wire brushing, and clearing out with 90 psi from the compressor


getting it started, sorry but i have no progress photos as anything this paint touches, i'll never get it off, so wearing old car-work clothes, along with eye protection and nitrile gloves i got to it.

20181102_155913.jpg
and afterwards, 5 layers of fibreglass across the whole area, smoothed out nicely. It will harden over the next 24 hours, leaving it for 48 and then will paint it.

20181102_163905.jpg

This job is a pain due to the lack of access and room.

However, looking on the other side...


The battery tray looks quite good
20181031_151931 - Copy.jpg

and underneath it...

lots of random debris, but no rust :D
20181031_152113 - Copy.jpg
and inside the hinge area...

NO RUST !!! :D so, one good side, one bad side. But i decided to do some preventative stuff and decided to clean and fibreglass coat it any ways.
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mathuisella
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Re: Coupe to road

Post by mathuisella » Mon 05 Nov, 2018 12:22 am

So, 48 hours and the miracle paint and fibreglass has cured nicely time to paint...


I painted it red to make sure i cover everything and can see it...
20181104_152424.jpg
and then painted over it black again. This way it has 2 coats of paint over the miracle paint + 5 layers of fibreglass.
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tsharkey
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Re: Coupe to road

Post by tsharkey » Mon 05 Nov, 2018 2:17 pm

For a Vic roadworthy I was once knocked back because of the rust you described. The tester said unless I use metal to repair (ie: Cut it out and weld new sections in place), he would not pass me. Claims fiberglass no longer allowed to repair ANY rust. A pretty hard job given the space confines. I repaired similar to how you described and took it to another assessor who passed the car without question. Lesson learnt was to go after all rust before inspection, otherwise, to satisfy the requirements, there will be expensive repairs.

Great that you have stopped the internal leaking.
W123 1981 300TD - Family Kid mover
W202 1998 C250D Factory OM605A Turbo - Partner's daily driver
W123 1982 300CD Retro fitted OM617A Turbo - Mine
W123 1984 300TD 5 Speed Manual, to teach the kids how to drive
W123 1982 300TD Factory OM617A Turbo (Hans) - Project
W123 1985 230TE - Brother's
W123 1985 300D - Sister in Law's
1962 S-Series Valiant (Tho Daimler & Chrysler divorced, still part of the extended family)

Past benzes
W114 1969 250CE - PO put in an M110 transplant and nearly sent me around the bend
W123 1981 300TD - "Matilda" - RIP hit front side & rear but left my brother + niece A-OK

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mathuisella
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Re: Coupe to road

Post by mathuisella » Thu 08 Nov, 2018 5:38 am

Cheers for the reply :)

wow, pretty crazy about the guy not passing it, was it the same as mine, a small hole smaller than a 5 cent piece in a spot that was impossible to get to without risking damaging other body panels.

I have a guy that has done my cars before for roadworthy checks, he knows i'm not made of money, but i put in a lot of time and elbow grease to do things well and won't fail me because of something silly like that.

mathuisella
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Re: Coupe to road

Post by mathuisella » Sat 10 Nov, 2018 11:27 pm

recap > Car has weird noise on cylinder 4/5

opened it all up and took off the rockers ect:

And i noticed this...

it 's been covered in oil and there since i got the car :O hiding away making a weird ticking noise.
20181015_141228 - Copy.jpg
glad it's out now and noise if gone.


However, my glow plug relay has gone :'( Cheers tony for the chat today and pointing me in the direction.

Cracked it open to see if it's an easy fix
20181110_164230.jpg
resoldered each connection with leaded solder.
20181110_180718.jpg
still no go, so looks like i'll start testing individual components on the PCB

likely the capacitors or the IC is to blame and will need replacing, but we'll see.
20181110_180701.jpg
Cheers TSharkey for the chat :)
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Tony From West Oz
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Re: Coupe to road

Post by Tony From West Oz » Sun 11 Nov, 2018 12:07 am

The buzzing noise from the GP Relay was the relay pulsing.
When the relay is open there is enough voltage to pull the armature in.
With the relay closed, 12V goes to the GPs, but the current causes the voltage to drop, causing the relay to open. The voltage rises again . . . . . causing the buzzing sound.
This could be due to a high resistance on the strip fuse (>0.5 ohm could cause this issue).
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (SOLD)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

mathuisella
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Re: Coupe to road

Post by mathuisella » Sun 11 Nov, 2018 12:35 am

Tony From West Oz wrote:
Sun 11 Nov, 2018 12:07 am
The buzzing noise from the GP Relay was the relay pulsing.
When the relay is open there is enough voltage to pull the armature in.
With the relay closed, 12V goes to the GPs, but the current causes the voltage to drop, causing the relay to open. The voltage rises again . . . . . causing the buzzing sound.
This could be due to a high resistance on the strip fuse (>0.5 ohm could cause this issue).
Cheers.

I'll get myself another multimeter to test.

I took the fuse strip off and it was pristine, not a hint of corossion.

mathuisella
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Re: Coupe to road

Post by mathuisella » Sun 11 Nov, 2018 7:59 pm

for the 80 amp fuse / strip inside of the glow plug relay box it's reading 0.3 Ohms. It fluctuates between 0.1 and 0.3 a little, but it's a cheap multimeter

Tomorrow I'll just bridge the gap with a small nail or something, and if there's no issue with glow plug circuit, then i know it's the fuse and get a replacement

Looking nice, but still much more to do
20181111_174023.jpg
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Tony From West Oz
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Re: Coupe to road

Post by Tony From West Oz » Tue 13 Nov, 2018 12:18 am

The nail may be a bit resistive. Bridge the gap with a number of strands of copper wire so the resistance is low.
Check voltage across the fuse when GPs are on. (even if the relay is pulsing, it will show a couple of volts - pulsing if you have an analog meter)
Regards,
Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (SOLD)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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