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W124 500TE Project - Lets do this!

jaymanek

E500E Guru
Member
MODERATOR'S NOTE -- 20-Nov-2017: This thread was accidentally deleted, but a full copy was saved, during the addition of the code that automatically downloads externally hosted images. We are re-creating the thread with jaymanek's posts, as the thread was originally posted. Unfortunately, we are only able to recreate Jay's posts at this time.

The full original thread, up to this point, can be downloaded in PDF format at this link.



Here we go again… Some say it’s the V power running through my veins, some say stress causes irrational behaviour… My wife says I have an irreparable genetic condition.

Whatever it is, I get an idea and I cannot rest until its done with.

After the completion of the W123 manual 560 project, there was a gap in the “ongoing build” department of my left cortex.

I love my 500E and I love my 3.4 AMG Estate.

We spend most of our miles in the wagon as its practical, comfortable and a lovely motorway cruiser.

For me though, I always miss the 500E grunt when I drive the 3.4..

The straight six is a lovely “sewing machine smooth” engine, but it’s never going to have that V8 character…

So of course, I started looking around on the internet in search of fellow escapees of the cuckoo’s nest and found a few… mostly Japanese or American.

I even found one such member, whom we shall call “Nor” (real name heavily disguised for privacy) who considered selling his converted V8 wagon. I sent this mysterious “Nor” a message on Facebook. I got no reply.

I started looking into what it may take to create such a car. Well I need a M119 drivetrain and a suitable estate of course.

Well it just so happens that we have a lovely E220 in stock at Mercland. It’s a lovely car that our own team have breathed upon over the years.

To convert a right-hand drive car, my best chances are a M119 from an early R129 I would think? The early R129’s used KE Jetronic which is relatively simple to wire up and get going... RHD steering box may be an issue here, but we can solve that surely?

A few weeks go by, busy with work, until I googled once more. I see that fellow inmates talk of chopping backs off cars and welding them to a 500E saloon… hmm sure I saw something like that on crimewatch once… didn’t end well. Not a big fan of this method.

Then I see how “Nor’s” car was built. To do this conversion well, you really need as many 400E or 500E parts as possible. Essential are things like the engine support, modified firewall, 500E engine Transmission, Diff etc etc.. Then there are the body panels to think of. If we are doing a 500TE then lets do it properly.. We need flared arches, we need suspension, we need brakes….

The items become quite an excel spreadsheet.

So I slowly steer away from the E220 we have.. don’t think that would work.

I realised to do an authentic 500TE, it has to be a left hand drive with as many genuine 500E components as possible.

I post on the book and of course instantly I get people offering me parts… awesome!

Within a couple of days, I seem to have secured most of the body panels I need, but hardly any of the mechanical bits… Why aren’t people storing 500E engines complete with body shell in their sheds?

Whilst my new buddy from Germany, “Roland,” is figuring out how best to bend side skirts to fit into an envelope, I start looking into where to get the drive train parts.

Surely I wont have to try another search engine? Bing? Yahoo?? Are there any more?

Just then “Nor” from the USA replies to me… “Ill call you tomorrow, still have the car.”

Awesome, that’s that then…

The next day I speak to “Nor”… A lovely gent, but clearly one of “us” crazies from the asylum.

“Nor’s” price is a little high for the car, but by now I’ve started to total things up on that spreadsheet I began earlier… The numbers are starting to look like those I used to see during my days at an investment bank, and that’s without some of the essential parts required.

We tentatively agree on a figure for the car subject to “Nor” looking into shipping logistics and prices.

A few days go by and I didn’t hear from Nor.. I poked him on the book but no response.

I figure he has changed his mind.. I don’t like to chase… I know when I’ve been dumped…. Just got to man up, listen to a bit of Whitney and accept it.

Another enthusiast contacts me.. He knows of a nice 500E that been stood for a few years that runs great and has just had a load of $ spent to make it lovely.

Unfortunately car is in Guiness-land.. and not the right side either… all the way on the other end, probably nearer Nor than me.

I have to do this by phone… I speak to the Irishman… he describes the car as “sound” and that’s as much information as I have… Not entirely sure of his blood-guiness content at this point, but he seems pretty honest for an Irishman…

I buy the car based on one or two passport sized pictures and the word of a fellow nutter. This car is not cheap, but a little cheaper than what 500E’s are fetching now. Its a whole 500E that I can use all the bits from and transplant into a wagon…

Then casually surfing the bay and a high mileage USA import 500E pops up.. Ok this is interesting… the body is described as rust free… The engine/box are described as running perfectly.. The pictures show the seats and interior are worn but who cares? A quick note to code name “Eddie” reveals that his asking price is in the land of the fairies, even more that the price I have committed to for the Irishmans car…

So we sit patiently twiddling our thumbs waiting for a transport company to collect unseen, untested and quite expensive 24 year old E500… A few days go by before Shane calls to say he will be on the way. So I send my childrens lunch money off to unknown Irishman and pray to all gods of all religions that he is of fixed abode and good moral stature. Will this be an Emerald or a Leprechaun?

Thursday night comes and being a Rock and Roller, I am sat in my office advertising C220’s..

Up pops a little box on the bottom right of my monitor… “high mileage 500E ending soon”… Ok well lets take a look.. I put in a cheeky bid… its somewhere between what I think its worth on terra firma and Eddie thinks its worth sat up high on those clouds…

I close the internet page and advertise more C Classes.

“Congratulations, you have won..” stomach feels a bit funny now…I appear to have purchased two 500E’s, a full 500E bodykit and various smaller parts.

So as I convince myself that “all is well, you are a car dealer, you can just sell the Irish car, assuming it turns up…. ” Is there any lunch money left? I don’t think so… Going to have to sell the kids… Ah well, six years is a good run.

Eddie was on the phone within minutes highlighting his 48-hour collection stipulation on the listing which I had man-read a few days earlier…

I rang my mate TJ… “We are off to Preston very late tomorrow night after work.”

Having known me since childhood, his reply carried a cocktail of unsurprised/disappointed tonal characteristics..

TJ knew I must have spent money on something that ranks lower than the need of my children’s school uniform..

I gather some pennies together and off we go on our adventure up Norf. Praying all the way that my wife didn’t enquire as to my whereabouts.

I wasn’t expecting much from this car… It has done a few trips on those Highways.

I didn’t bother with a test drive at 10pm. We paid Eddie and off we went.

Woah, this thing is quick… It feels quicker than my 500E… maybe the miles really do help to loosen things up… or maybe someone has simply fiddled with the throttle to make it feel quick… I don’t care.. I glance at the oil pressure which reads “3” and the engine sounds sweet enough.

Of course the interior is tired and has been tarted up for sale, probably by Chuck from over the pond...

A thorough thirty second examination was carried out in a dark corner of the wild bean café in Kirkham.

My iPhone torch revealed that he body panels are indeed totally rust free… Cool, so its decided, this will be the donor.

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Just as I was updating my spreadsheet with the amended list of required parts, the apple vibrates..

Guess who?

“Nor” gets back to me… he has a price for shipping and has done all of his homework with regards the various shipping methods…. Over the preceding days, Nor had been busy evaluating the various quotes. He had been wrapping up the spare parts to come with the car, to measure them for more exact quotes…

Uh oh…

I now have two 500E’s.. a complete set of 500E body panels about to enter my letter box anytime and many, many, non-returnable parts from Mercedes on the way.

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How do I handle this? Well I certainly have gone too far to turn back… I could sell both 500E’s and beg Mercedes to take some of the parts back… But that will take time and I simply cannot invest any more money without me getting hurt… hurt real bad, by the boss.

This is annoying… Why aren’t I more patient… Why didn’t I trust in humanity… of course Nor was always going to get back to me.

Days go by and I realise there is no way I can buy Nors car… The desire is strong but I must confess my sins to Nor. I hope Nor is not too upset or offended. I have been messed around so many times over the years, I know how it feels… You really want to punch something really hard… I was thankful for the Atlantic ocean between us.

Thankfully Nor took it graciously and we even hope to meet up at some time next year. Ill be the one in the baseball helmet.

Whilst all of this was going on, In the back of my mind I still needed a suitable wagon… where do you find a left hand drive estate car with the spec required to make this easier for me. I needed Left Drive, 280, 300 or 320, ASR traction, cruise, black leather, ideally 7 seater, heated seats and NO structural rust. Tried ebay with not much luck.. It has to be Germany surely? Surprisingly, although hundreds pop up on mobile.de, very few of the cheaper cars have the essentials I need.

I loathed German at school.. So when talking to germans about W124’s, “je voudrais un pain au chocolat avec fromage frais” wasn’t getting me any answers about the condition of the subframe…

Hmm, who do I know that speaks German and knows about cars…. Oh yes Roland!

Roland made some phone calls and saved me from some very ropey cars. I would have bought one of them otherwise! He educates me on postal codes to buy from and those to avoid.

A few days go buy and not getting far, when something catches my eye on Germanic ebay. A very poor advert. I had dismissed it earlier due to the pictures not showing any real detail. Upon a google translate of the advert I had learned all about the sellers deep affection for the car but nothing about its spec or condition. I emailed the seller with a google translate of “do you speak English”. The answer was nein. Roland did the honours. Next day Roland “pops” over from some 60km to view the car for me.

He said “it could work”… Has all the things I need and only superficial rust. The seller is an older genuine guy and has had the car forever. Some W124 usual gremlins but nothing that affects my plans.

The car is not cheap.. Germany is not a cheap place to buy.. I guess due to their strict MOT’s. Its much more expensive than that lovely E220 I am selling at the moment.. but its what I need and cheapest I have found.

So a deal is done. I arrange transport with a local company to me.

They let me down after trying to double the price. I contact other transporters. Some are ridiculously expensive and some are just far too cheap to want to trust.

I decide there is nothing else for it.. I will have to make a day in my current 24/7 work diary to go and get this car.

Over the intervening days, the Irish 500E turned up… wow. What a car. Drives like new. Unfortunately, the paperwork consisted solely of an old blue V5 and a note from the Irishman thanking me for the business. Odometer shows 83K KM.. Looked around for tell-tale wear and its easy to see that this car has had an easy life.. could be genuine mileage.

I went for a drive… Lovely car… way too good to break up.. and in reality, way too valuable for this project. This will be for sale soon once we tidy some bits up and get it recommissioned.

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Friday came. My eldest and I got on a plane to Dusseldorf. After paying the taxi drivers mortgage off, we got a good nights sleep for four hours.

A quick croissant and then I look out for a W202 running on LPG as instructed.

Roland had volunteered to collect us and help with translation... I know there must be an “app for that” but there is nothing quite like trusting a German guy you have never met before.

So we arrive at a house in some village with only “E” data reception showing on my phone. This place is on par with an African tribal settlement in terms of data connectivity.

Now I really feel like Michael Brewer. I buy and sell thousands of cars a year but for some reason, buying a car privately like this, is always different, warmer somehow… You get to know a bit of the history of the car rather than just some specs on the monitor. I was feeling glad I had made the journey.

So exchange of documents and then I get to see the car for the first time… Yep it’s a LHD W124.. yep it looks like it has paint on it in most parts and yep it starts… Lets go!

Just then I see the son of the seller in tears… It was obvious that selling this car wasn’t an easy decision for this family. The father and son got emotional so we stopped for a little photo… We took some time for them to say goodbye.. Not quite sure how long they owned this car but the teenage boy indicated that it’s the only car he has ever known.

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Its been a long time since I bought a car like this and it reminds me of the special relationship that we form with these metal cans..

Will panasonic cars have this effect? I don’t think so.

In true used car sales spirit, the fuel lamp is on and needle barely moves. Off we go to find a station… We made it thankfully… Tank full and we head for the Autobahn… woohoo, never driven on German roads, 260 KMH here we come… We wave goodbye to Roland with an exchange of hazard flashes. Roland is a new Mercedes friend for life now.

Well before I got the chance to test the range topping 320 torque, the temperature needle flew off the top of the gauge… uh oh. So first things first… post it on facebook..

Stay calm. we have breakdown cover, we have stolen croissants from breakfast and a ¼ bottle of Evian… We have seen three and half episodes of Bear Grylls… nothing can break us.

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With the thought of spending the day waiting for ze RAC on the autostrassebahn, I pulled over and opened the bonnet.. Straight six sounded normal with that old car engine smell… no steam, felt the hoses, seemed ok.. no excess pressure.

Hmm, breath out relief but a little scratchy on the head….

Then I remember an old method passed down through generations of Maneks.

I took my left fist and beat the dashboard.. Hey presto, the temperature was a steady 80 again.

Utilising the phrase of our very own northern member, John… It was the standard equipment “comedy W124 gauges” playing tricks on me. And it tried to scare me all the way back home, bouncing up and down...

The 250 mile or so journey to Calais felt a breeze through Netherlands, Belgium and France.

We were on the train by lunch time and back in the UK..

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This is where we are at now and hope you are interested to follow the progress.

Will the wife find out? Will I live to tell the tale?

It may work, it may not, but in the words of my spiritual prophet and guiding force…

“he who dares wins Rodney, he who dares wins…”

Apologies for any mistakes in my grammar.. I only went to a cheap school and never really listed to my teachers.

Apologies also, for what has ended up being a very long post. Future updates will be brief and picturesque.
 
Hi All!

Mini update.

Earlier this week I removed the dashboard, door cards and rear seats ready for them to go off to be redone.

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I will be using some Recaro CSE seats for the fronts. Still looking for correct adaptor brackets if anyone has any. Recaro number 85.51.09/09.

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The trimmer I am using this time is a Recaro dealer..

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The wood will go off to be refinished

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Parts are arriving daily. Thanks to the eagle eye'd member who pointed out that I had ordered the wrong control arms..
Went with genuine MB parts, so expensive but at least they will last forever.

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Last couple of days I found a few hours to remove the engine, Gearbox and main drivetrain components from the 500E.

Im hoping to do the same for the Estate car in the next couple of days.
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Engine & Gearbox are now out of the Estate

And just for comparison
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Hi All!
Last couple of days I have been stripping the engine down. Took me all afternoon to strip all of the ancillaries from the engine yesterday.

Today I stripped it down to heads and block.
It will now go off to the engineers to test and refresh where necessary.
It should hopefully come back looking a lot cleaner!

A large order came in today. Mostly parts for Rear Sub-frame & Suspension.
Also some parts for the engine refresh.
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Oh when I removed the valve covers, I noticed that the right exhaust cam was around a tooth out.. Im guessing this may have been the cause of the slightly stumbly idle once warm.

I guess it could also indicate chain stretch? The other three cam timing holes lined up perfectly.

Either way its getting a new chain and tensioner.
 
Do you know what it means when a three year old boy whispers, “its coming?”

What could be coming?

Well back to the build.

Weekends are the only time I can use my own ramps at work, as they are in constant use.

Friday afternoons one of the technicians finishes early and so I take a few hours out to make some progress.

Plan was to swap rear sub-frames over by the end of the weekend. Well we would have to in order to be able to get them out of the workshop ready for Monday.

We pushed the saloon onto the ramp and I started disconnecting all of the bits and pieces attached to the rear sub-frame.

First the springs have to be removed which is very easy on these cars with the correct tools.

Then the handbrake cables and brake sensors were disconnected. Once everything is out of the way, the complete sub-frame was lowered off the car.

Once the 500 sub-frame was out, I set about replacing every suspension arm, link and bush on the axles. The sub-frame bushes were the most time consuming as they were pretty well stuck in.

The 500E has been a joy to dismantle so far as there was no rust anywhere. No seized bolts, no rounded off nuts.. most of the underside is like the day it left the factory.

The sub-frame was in nice condition also. No point painting this as I had considered, it came up great after a wash.

Now that the sub-frame was out, the next task was to remove all lines for fuel and rear suspension.

I had already ordered all new hoses and metal pipes for this. Unfortunately some of the front to rear metal pipes for both suspension and brakes came incorrect. Too long, short or with the wrong ends. Mercedes tend to do this with brake pipes, no longer come in the correct form.

So on Friday night I labelled and removed all the pipes from the 500E. They were like brand new. Never seen a used car with such clean metal lines.

Got home quite late on Friday after catching up with work and nursing my bruised finger which id struck with my large hammer earlier… those sub-frame bushes.. grrrr..

Fellow housemates not too happy with my choice of perfume as I walk in… A unique cocktail of 97 RON, DOT 4 and ZHF fluid.

Saturday afternoon came around. We put the estate up on another ramp and I started dismantling the sub frame. All went well and it was out pretty quickly.

The sub-frame is very different. The 500 sub-frame is mostly tubular. The regular is much less heavy duty. See pictures below.

Luckily I couldn’t see much difference between the mounting points. I was worried there may be some differences between saloon/estate.

I removed all of the brake and suspension lines for the estate. These were NOT in the same condition as the 500E! Most were quite rusty.

Wife and the kids were to be out so I had the evening to carry on.

I couldn’t have done any more sub-frame work as I needed people to help me lift it into place.

Early evening on Saturday I started swapping over the steering parts. The 500E box is quite compact in comparison to the standard item.

The rest of the steering gear is all R129 and has to be swapped also. I have ordered all new links and track rods etc but they have not yet arrived. It took me a few hours to swap everything. Plenty of tight bolts and plenty of beating required to release those steering arm joints from their homes of over 25 years. I was still pretty upset with the hammer so it took a bit longer.

Somewhere that afternoon I had also offered up the pipework to the estate. Surprisingly the pipework was pretty much spot on. I didn’t have to bend it much at all. It all lined up really well.

The saloon and estate have the same wheelbase so I guess it makes sense.

There are more pipes on the 500E though as due to ASR, the brakes all have individual lines from the pump to each wheel.

I used the 500E fuel pumps. The estate also has a “pre pump” to aid fuel getting over the sub-frame to the fuel pumps which is mounted under the rear seat. I left this in position.

I only had to extend the return fuel line due to the different position of the fuel tank.

All of the suspension pipes including flexi pipes were changed to new. The 500E lines run down the right of the car to the engine bay whereas on the estate they had originally run the left side.

The suspension spheres were replaced whilst I was in there.

So in short, everything was swapped to 500E spec.

Around 9pm Saturday I went back into the office to finish off with work, which I had been doing in between spannering.

I get a phone call. I know who it is before I answer it. I sense the impending doom. Yep, she was pretty upset. I had misunderstood. I was supposed to be home to watch the kids a lot earlier, whilst she went out.

So I did the best thing any male can do in this situation. I stayed at work and advertised cars until I knew it was safe to go home.

Sunday morning I was feeling pretty tired.

Not sure if it was all that lifting of sub frames and heavy steering boxes, being shouted at or just lack of sleep.

I swapped over the anti-roll bars complete with new bushes.

The original self-levelling valve from the estate had to be used.. This is because the 500E uses one supply from the valve to both shocks. The estate has two ports, one for each side. So I went with the estate version as I had already run all new pipes to the shocks and used all new estate specific parts for this.

Anyway, both sub frames were out on the floor ready to go back up.
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I had to swap the spring perches (or carriers) over as the estate has slightly different shock absorber attachment to the saloon.

With the assistance of the entire sales team at Mercland the sub-frame from the 500E was lifted into the estate. Thankfully all lined up and it went up into position with minimal fuss.

The same was done for the 500E.. if nothing else just to keep it mobile on its wheels for pushing around.

I then came to fitting the H&R lowering springs to the estate. The boxes had the correct part number on but inside the springs looked like they were to fit a Hummer.

Very angry email sent to supplier. Kicked the bin a few times. Feel better.
I fitted the original 500E springs to the estate (looking like new of course).

All of the brake/suspension lines were properly attached to the body using the original clips/mounts from the 500E. I will need to check that nothing is fouling the rear anti roll movement bar once it’s all up and running, but looks good for now.

The 500 springs make the rear sit quite nice… So maybe I won’t bother with lowering springs after all.

Following Saturdays mix up, I had been given a strict deadline. I HAD to spend time with my offspring.

After a thorough tidy up, the cars were pushed back out of the workshop and all of the thousand and one tools that I had amassed on the floor, were cleaned and put away until next week.

A well-deserved family trip to TGI Fridays helped the relaxation required after a pretty busy weekend on the cars and running a business concurrently.

My son’s inquisition into the name of the restaurant as to why it implies that it only opens on a single day each week, took up any remaining patience.

As the weekend comes to a close, I like to lie in bed and fall asleep to a bit of Netflix.
Just as I select “Daddy” on the Netlfix welcome screen, the young son whispers, “its coming.”

Like all of you, I wonder what may be coming? Could it be Christmas? The rampant screaming and running around that my wife displayed indicated I was in for more of a disaster… But as always I could not decipher ‘hysterical woman speak.’

So I continued with the possibilities in my own head.. hmm It’s a little early for the apocalypse.

Well I probably should have mimicked my wife, as a split second after the words had left my sons mouth, it was very clear what was coming.

Yep… The £6.99 meal deal was refunded to me in liquid form on my chest.

That was my weekend!

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Today I sent off some engine parts for cleaning.
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And took delivery of some refurbished items ready for installation.
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Sent off wheels that I plan to use for refurb
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Also sent off exhaust manifolds for coating.



Hello all... Today I spent a few hours stripping the interior out so that I could trace the wiring loom back.

Its been a frustrating day, following cables back from the battery in the boot all the way to through the car and into the engine bay.

The complete relay box is now out and the entire engine bay wiring harness is out of the car.

Not an easy job but im glad its out of the way. I had been dreading it.

I still need to remove the wiring harness for the instrument panel, Ill try and complete that tomorrow...

Now that its out it doesnt seem too complex but I will keep queit until its in the estate and until it actually works!

I cant understand why the estate car has a speedo cable being a 1994.
The 500E doesnt have one and I cant recall seing a cable driven Mercedes speedo since the 80's...
 
Hi everyone,
The last few days I have been busy with the wiring loom from the 500E. It took me some time to free it from the car.
I had to follow the cables from the battery in the boot, to the engine bay, to all of the connector blocks and carefully pull it all out whilst labelling every connection.
The toughest part was the wiring loom inside the car. It is about 3x as thick as a regular W124 interior loom. It weaves in and out of various areas of the dash and all has to be picked out…

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I had to remove most of the remaining dash, the steering column etc etc. I had to unscrew each and every wire from the fuse box, carefully labelling each connection.
One night I took the whole lot home and lay it out on the floor.

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I then had the joyous task of carefully following each and every wire, removing the bits for the A/C, Stereo, Sunroof and so on. The wires I needed were the ones that affect running of the engine, gearbox and everything to and from the instrument cluster. It took me about five hours and one very sore back.
I don’t think I will know if I’ve made any errors until I try and run the car! I hope not!
I just need to tidy the wiring up and make it look like a loom again. Then eventually ill need to offer it up to the estate and splice it into the existing wiring where necessary.. Oh fun.
Over the weekend I took a break from wiring. Since the differential and reconditioned drive shafts were looking at me with their pretty new paint jobs, I decided to get the rear end complete.
The sub-frame was mounted last week. However there were some parts I wasn’t happy with.
I had already changed all of the suspension arms but the shock absorber bottom ball joints were totally shot. So I had ordered a pair of new shocks… £££ ouch.
Also the bottom ball joints on the rear hubs didn’t look great.
That was not a fun job to replace. Broke my special tool that I’ve had for years. Had to resort to making my own out of a head bolt and two large sockets..
So all of that was replaced and I mounted the differential last night with the drive shaft’s.
It was a bit tense when hanging the diff, as it looked like the brackets for the self-levelling valve and also the suspension spheres were going to catch the diff flanges… The suspension spheres are mounted differently in an estate to a saloon.
In the end, when the diff was mounted and left to hang, the parts all cleared each other by a mm or two! Almost like someone at Mercedes had designed it all to work together.. I may need to take my “adjustment stick” to one of the suspension pipes, but I’ll do that later once things have settled.
The rear end now has

  • 500E sub-frame
  • New sub-frame mounts
  • Reconditioned differential with with genuine Mercedes fluid
  • New self levelling shock absorbers
  • 500E springs
  • New suspension pipes both solid and flexible parts.
  • 500E wiring harness for rear axle
  • New anti-roll bar bushes & drop links
  • All new suspension arms
  • Reconditioned driveshafts
I did take some pictures of the rear axle all in place, but some wally left the memory card in the PC so none of them saved.
Ill get some later.
 
Hi Everyone,
Hope you all had a lovely weekend.
Last week I finished off the wiring loom. All taped and sleeved and hopefully when it eventually goes in, it all works! I keep having mini panic attacks wondering if I have cut wires that are required, hopefully all will work.
One major part of this conversion is the metal work required. Since I started the project I have been trying to find an experienced metal worker to come to us and carry out the transplants required.
I could have done it myself with the help of the Mercland technicians. However this level of metalwork is best done by someone who does it day in, day out.
I tried various welders that I know. One just ran off, one fell into fits of laughter and the last just looked at me as if I was asking them to weld me an Eiffel Tower.
Last week I dusted off the old yellow diary. The type that I used before the advent of digital cellular communication. There he was, back in 2008… The chap that welded the flares to the SEC widebody…
So I went to see him last week. I approached with caution as he was holding a blow torch. I talked, he seemed to listen. After a few deep breaths and shrugs, the deal was done. He would come over to our place with a hacksaw at the weekend, for a sum to be determined once the job is complete.
Im not sure payment in Pizza will work this time. May have to sell another child.
On Friday night I set up both cars on the ramps and I removed all of the suspension and steering parts from both cars.
Saturday morning, at 7am, Chris turned up wielding his sharpest chisel.
We need to transplant:

  • Front Crossmember / Engine Support
  • Left and Right Firewall Panels
  • Parts of the Firewall down to the Transmission Tunnel
  • All brackets for engine ancillaries
  • Radiator Support
  • Steering Damper Mount
After stripping away the seam sealer, the cross member can be removed by drilling out the spot welds and cutting through any seam welds.
The estate car was just spot welded but the 500E had both spot and seam welds. The dude at Porsche took his job seriously.
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Chris then started to remove the left and right firewall panels.
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A view from the underside
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These are both of the cross members out.
The 500E support is basically a R129 panel.

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We weren’t anticipating having to cut out the sections below the firewall panels.
However once the top panels were removed, it was obvious that this section had to modified to allow the V8.

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So instead of “unpicking” the whole of this double skinned section which extends from transmission tunnel up to the suspension towers, Chris decided to cut out the sections that are different, and weld just those parts in.

This is the 500E with that section now removed.

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The 500E cross member was “tacked” into place on the estate. This will be spot and seam welded later.

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This took us up to 6pm Sunday.
I then reinstalled suspension on both cars. The estate had all new parts for steering and suspension. The 500E steering parts, hub and brakes were taken over to the estate.
The brakes will be upgraded again later for larger items.
Chris will be back to “finish off,” although I think there is still a few days work to finish the metal work.
The cutting of the estate will need to be a lot more precise to ensure a perfect finish.

Some shiny parts arrive back to keep the motivation up. Ceramic coated. Sorry I don’t care what anyone says.. The spray on stuff just doesn’t last. This is the only way when it comes to exhaust manifolds.

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My plan now is to offer up wiring inside the cabin when I get time. I need to find a suitable spot for the battery in the luggage area and then the rest can be routed.
That’s it for now!
 
Hi everyone!

Over the last week, I have done some little jobs whilst I wait for Chris to complete his bit. I had a call from the engine builders to say that the block was ready for me to collect. I didn’t realise that they would not be reassembling the block back to how I gave it to them. Upon collection, I was given a clean and honed bare block. The crankshaft and all of the pistons and other loose parts were in a box, cleaned but in bits. Apparently, unless they do a complete engine build themselves, they won’t reassemble as a policy. As I had given them the block and heads separately, they would not build the block back up. Something to do with their liability.

I wasn’t too happy with this as I hate assembling something I didn’t take apart.
I took it over to another engine builder/friend who will check everything and build the bottom end with all new bearings that I have supplied. The original engine builder still has the heads which required new guides and valve stem seals. I am promised the heads will come back to me complete and built up… Lets see..


Old Valve guide vs New (Genuine Mercedes Part)
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Chris the welder couldn’t come in as much as hoped last week. Chris hurt his eye not once but twice on other jobs. That’ll teach him to forget to pull down the eye protection glasses from his forehead. His depiction of the hospital “Eyeball Polishing” procedure is not something I wish to ever experience. He did pop in one night. He managed to finish welding the cross member completely after checking it with a bubble in a tube.
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Chris then came back on Saturday afternoon to carry on with the firewall modifications.
The cut out panels were taken away to his cave and prepared ready to weld into the estate. We then needed to cut the firewall panel on the estate to the exact shape of the prepared donor items from the 500E. Our laser 3D mapping and cutting tool is currently on loan to NASA and therefore we used the next best thing. A section of a Supaloops box was cut to the shape required. I would have gone for Crunchy Nut myself. This shape was marked out on the estate. With some precision cutting from Chris, the estate was ready to receive the donor part.

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This is the lower section ready to be welded in.
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And the upper being test fitted

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The right side was all welded in neatly and the welds ground back (pic to follow).
Just the other side to go finish for Chris when he can find time to come back. In the meantime, I took the 500 instrument cluster apart to fix the non-functioning odometer.
After a lot of fiddly stripping down, I found a tiny little plastic cog was broken. I found a kit on internet and repaired it. Painted the needles to look a little fresher. The 500 fuel gauge wasn’t working when I picked it up. I’m hoping that was the sender in the tank and not the gauge itself.

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I would like a new or good used set of gauges as these have faded and yellowed a little. Haven’t managed to find any yet for a 500. I have also fitted the battery tray in the rear right wheel well. This meant sacrificing the rear washer fluid bottle. I plan to run the rear washers from the front washer bottle, as I was planning to blank off the headlamp washers in any case.

That’s all for now folks!
 
Picture of right panel now complete. Just need to prime and seal the welded area.
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I fitted the 500 wings and side skirts for a test fit. Actually, mainly to satisfy my childish impatience for the car to look like a 500.

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Well that’s that. The end of a long relationship. We all knew I was pushing it. She finally had enough and has left me. I guess I was just asking too much of her. Maybe she needed some time off from all of the ironing. She has her faults. She can be pretty hot headed sometimes. I can be demanding, I admit. I accept nothing but the best. Especially when it comes to automotive wiring. I need get on the internet and search for my new perfect partner. It’s been such a long time that it’s a bit nerve racking.
Portia the soldering iron has served me well for years, but around the hundredth wire she conjoined on this project, she spat her own head off.

I just hope that I can find another one just like her.

The interior wiring loom is now in. The scary thing is that I really cannot test it until the engine is back in. I have no idea if I have missed anything. If I have it will probably be very head scratchy trying to figure out what went wrong. Time will tell!
I am having the rear seats heated. I decided to use the factory front heated seat switches to power the rears. That way the kids can’t play with the switches in the back.
Im making up a little loom for this.
The Recaros have their own built in switch panels of course.

Talking of which, I had a call to say the retrim is ready for collection. Not that I am anywhere near ready for it!
 
Hi!
This weekend hasn’t been the most productive but I got a few little things done.
Chris finished the firewall metal work. Both sides are now in and the welds all ground back.
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He is to return in the next couple of days to transfer across some of the welded in brackets, mainly the ECU box bracket and also the one for ABS pump coil packs.
I have been concentrating on wiring. I tidied up the interior wiring harness. I ran the wiring and hose for the rear washer pump to the front of the car.
I made and installed rear heated seat loom.
I made and installed a simple wiring harness for the front recaro seats.
I fitted the main battery positive feed distribution block in the engine bay. This is located on the back firewall.
Also fitted a few miscellaneous brackets that I could do without affecting the work Chris has to do.
I now need to wait for Chris to finish his work, seal, prime and paint the welded areas.
Then I can go in all guns with the rest of the engine bay wiring, pipework etc.
I hope to have the bottom end of the engine back this week.
Once back, I will spend some time carefully building the engine back up.
After a sort out today I am finding that many little parts I have ordered from Mercedes, weeks ago, still haven’t arrived. I need to chase these.
I await the return of rebuilt Brake callipers from Big Redd.
I can then install the R129 “Silver Arrows” brakes.
During coffee break, I found these little cam oilers that sit on the head of the engine. Their job is to bridge oil over to the camshaft lobes.
The plastic ones should be replaced whenever doing head work as they go brittle. Once they get blocked or become brittle, the engine will sound tappety.
Originally these engines had metal oilers. I didn’t realise that my engine still had its metal cam oilers. I had already ordered replacement plastic oilers.
I decided to stick to the metal oilers. As you can see the seals become hard and brittle. I cleaned them all out with a popular penetrating lubricant and replaced all the little green seals ready to go back into the engine.

Carrying out this job on your son’s homework is not recommended.
One old brittle seal vs the new green one.
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These are the plastic oilers that Mercedes now supply.

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Interior arrived back today.
Feels like we are a long way off installing it!
Unwrapped the fronts for a quick peek…

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Tis the end of the world. I have man flu and so I am desk bound.
No spannering for a few days.
Chris came by on Monday night. Removed the remaining engine bay brackets in the 500.
Hoping he is here tonight to weld them all into the wagon.
We are realising that a LOT of sheet metal in the engine bay was different. The shape of the inner wings is different. The shape of the bulkhead panel is different.
Its not just the firewall and transmission tunnel parts as we thought.
Some of these areas shouldn’t matter too much, the differences are minor. We won’t know until the electrical and other ancillaries go back in.
Some more shiny parts arrive:
These are the SL R129 silver arrows calipers.

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Found a better steering wheel

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Engine Wiring Harness. The one on the car seemed ok but thought id go with a fresh one as they are biogradeable:

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Hello everyone!
It’s been slow progress this week due to my temporary demise caused by food poisoning.
It’s quite difficult to work on a car from the W.C. Terrible week long experience that I never wish to repeat. I can only describe what happened to my digestive system as a cross between the effects of a Stag holiday in Las Vegas and being kicked in the stomach repeatedly by Bruce Lee. You have to have been on a Stag in Vegas to know what I mean. The Bruce Lee thing you can imagine.
Chris has now totally finished all of the welding, transplanting, grinding and other spark producing activities. He came by and sealed the welds last night.
Today I have had Dave the painter come and blow some “199” over the engine bay. We have not gone for a totally concours finish here. There s very little engine bay that can be seen once all the trims, wiring, control units etc are back in place.
This now allows me to carry on replacing all of the ancillaries.
I still await the bottom end of the engine back, so this work will be a good time filler for the next few days.
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Chris will be back in due course for some more metalwork, but there is now no rush, as I can carry on with the powerplant…

Also fitted the brakes:

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Hi,
I am now starting to slowly get the engine bay built back up.
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These power steering hoses are completely inaccessible once engine is in. Good time to replace!

Chris came by with his cutter. Making noise again. We decided to use the arches from this 500E for two reasons. Everything has so far come from this car so it seems right to use these arches.
Secondly this car is totally rust free. Never seen these arches without any rust at all.

Few more pics later.

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Hello!

I have been building the engine bay back up.

I wish my memory was a little better. I labelled most things and took pictures, but some of the parts were still a head scratcher as to how they went back. Luckily I have the other E500 sat here in our showroom so I can use it as a reference.

Unfortunately I discovered that the wiring harness that supplies the headlamp, horn etc has a different connection under the fuse box. The 500 has a larger plug with more connections. I need to come back to this to figure out what the extra four wires are for.
So im still not done with wiring

Sadly Chris did not make it over the weekend but he did make a little progress last night.

The 500 quarter panels were cut off last week:

The wagon arch has been slowly trimmed back to the point where Chris could make a nice clean join to both the inner arch and the actual quarter panel.

When it comes to welding, it has to be done very carefully to avoid distorting the panel.

This is de ja vous from when we did the SEC widebody back in 2008. Same process, if not a little trickier as we have to go inside the door shut this time.
 

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Unfortunately I discovered that the wiring harness that supplies the headlamp, horn etc has a different connection under the fuse box. The 500 has a larger plug with more connections. I need to come back to this to figure out what the extra four wires are for. So im still not done with wiring
Jay, the headlamp wiring harness is 036-specific since the headlights work differently than on any other 124 chassis. On normal 124's, the H3 bulbs inboard on the headlamps (near the grille) are operated by the fog light position on the rotary switch, and there are no bumper fogs.

On the 036, the fogs are in the bumper, and the inboard H3 bulbs turn on with the high beams as auxiliary pencil-beam driving lights. This is likely why where are extra wires. It is NOT fun to extract this harness, but it should be plug+play in the wagon. Several years ago, I extracted this harness from my 036 parts car for the in-famous "Nor" mentioned back in post #1. I sure hope he used it!

:shocking:
 
Thanks.. I think I should be able to make it work. I just need to trace the wires back and then wire in accordingly.

Priority now is engine build since I got the block back today...

A missing heat shield on firewall is driving me nuts. I suspect someone here at work threw it away by mistake... and guess what, no longer available from MB.
 
A missing heat shield on firewall is driving me nuts. I suspect someone here at work threw it away by mistake... and guess what, no longer available from MB.
D'OH! What heat shield do you need? Can you post a photo? Maybe someone has what you need laying around...

:doh:
 
I can help with any (non V8 specific) heat shield. I’m in NI so postage isn’t an issue either. I have access to a m104 Estate parts car and will be in that yard Saturday week. Assuming it’s one from your estate that’s went awol that is!
 
I have all the shields from the estate but i need the 500E specific one.

Part number I can see on my pics is A1246824071 or maybe A1246821071... but on epc i only see A1246824571
 

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I have all the shields from the estate but i need the 500E specific one.

Part number I can see on my pics is A1246824071 or maybe A1246821071... but on epc i only see A1246824571

Your looking at the drivers side (left side), part number in EPC, which is correct. Your first guess of the P/N in your pics is also correct, (for the Right side P/N).

So I think you need to buy A124 682 40 71, it shows up in parts listings on line, i don't know if it's really still available. Great Project.. I look forward to your updates..O
 

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Thanks, yes its 4071 I need but no longer available. I will try and make one from the wagon heat shield... after all it wont be visible when engine is in but needs to perform its function.
 
I have started engine assembly today.

These also arrived - engine mount cooler ducts. How cool is that, pipes especially dedicated to keeping the engine mounts cool!
 

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Very cool project, but one question: Has the block been honed? Coz it looks like there are honing cross hatch patterns visible. After honing there must be the silica treating performed to etch off the aluminum. The cylinders should then look matt and the honing pattern should be disappeared.
 
Very cool project, but one question: Has the block been honed? Coz it looks like there are honing cross hatch patterns visible. After honing there must be the silica treating performed to etch off the aluminum. The cylinders should then look matt and the honing pattern should be disappeared.
I was wondering about that too! The cylinder walls look funny to me, but I assumed it was the photo or camera flash. Better to figure it out now before the heads go on.

:duck:
 
Hi,

I will ask the engine builder tomorrow, but both the company that honed the block and the second one who assembled it seemed happy with it.

The walls are super smooth but you can see the cross hatch patterns.

It is a bit late now, the heads are on and torqued up this evening.

I will still check it out though.
 
Yes better check that out. The cylinders are smooth after honing but the silica treatment is a absolute must. Cylinders should look like:
 

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Cylinders should look like:
Yes, that is what I was expecting as well.

Jay, do your engine builders frequently work with Alusil blocks? Hopefully you have some higher-resolution photos to check out, or if the oil pan isn't on yet you can look up from the bottom.

:detective:
 
I have done some googling and it looks like they have carried out a traditional hone. The final Silicone paste stage has not been done. Seems its quite a specialist process and not much about it on the net.

I have to speak to them but looks that way from what I can see. Question is, what are the implications of it not having this coating... as turning back now is going to be difficult...
 
In my Opinion the Enginebuilder as make an mistake.He works an "Kreuzschliff" as the normal steelblock.But with Alusil you you must take Accid and spezailtools to make the finish of the liners.Here in Germany is difficult too,to find Company that can doo with requermind from Mercedes Repair.I think in Mercedes WIS you can find some Documents "How toodoo Repair Alusilengine Liners"
The Surface must be after prepairing not shining and no scratses from tool more "Satienirt or Matt",Soory i cant find the Englisch Words.Markus
 
Thanks Markus. He did seem to know all about alusil but it does seem the final stage using silicone paste has not been done. Im guessing this company did not have the equipment required.
 
Aye caramba! The good news is, you caught it before the engine was fully assembled and fired up. Bad news is, it will have to be taken apart and the block properly etched. If not, I'd expect very rapid wear on the rings & cylinder walls followed by engine failure. Rouven036 (or Jono) may know more about what happens if you run an engine without etching.

More info on Alusil treatment is in this document (link below, file also attached to this post):
http://www.w124performance.com/docs/general/aluminum_engine_reconditioning.pdf

:runexe:
 

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@jaymanek, question is, if they claim to know all about alusil blocks, why they deliver some work to a customer which is proven to fail?
Anyhow the block must come apart to perform the silicium honing/polishing. Good thing it will not remove a measurable amount of material hence the pistons etc can be reused. Another recommendation, check ring play in the pistons, there should be only minimal play of less than 0.05mm otherwise replace pistons (they will pump oil). Check the pistons Ring gap in the cylinders too. Should be not more than 0.3 - 0,4mm. If its on the upper end or more, replace rings.
 
Jay - sorry to see that the machine shop appears to have missed that. Don’t be discouraged!

It’s just lucky that you posted a pic of the block and the experts here noticed the error before the engine was fully re-built and [FONT=&quot]potentially irreparable damage done.[/FONT]
 
Im a firestarter, a twisted firestarter… that’s how I feel, like taking a match to it all.

All was going so well. I had the engine heads on last night, ready to time up the chain etc.

After the above last nights update, a message was soon posted which changed my mood from mildly cheerful to one requiring the use of a straight jacket.

It had not occurred to me at all, but a member on the 500E forum noticed that the insides of the piston bores were not finished correctly for an “alusil” block.

The finish that the first engine builder guys did for me is a traditional hone which leaves a cross hatch pattern as you can see in the above pictures.

Apparently these blocks require a special three of four stage honing process which ends with a final hone using silicon paste which totally smooths the inside surface of the cylinder walls. This, it seems, is imperative unless I want to scrap my engine.

Thanks to the eagle eyed members who spotted this error.

After I read this post, I quickly started researching. I found many (two) old videos, made in the days of Beta Max cassette tapes, showing the process.

Ze German guy explains it best. I didn’t understand a word but the video says it all.
https://www.youtube.com/watch?v=Glja_6VanUs

This process is specific to Alusil bores and narrows it down considerably to M117, M119 and some others that used these blocks, if we confine to Mercedes. Porsche and some others also used these.

As these blocks are pretty much indestructible, we have never had to rebuild bottom end on one before and not many other garages have that I have spoken to.

After all if you have a problem with bottom end on M119, you would probably just buy a second hand engine for next to nothing. Unless it’s a 500E and the blocks aren’t readily available.

It became clear that No1 engine builder was not aware of this required process. It was done now but luckily I haven’t started the engine and no damage has been done. Decisions to be made.

I then experienced various psychological states.

Around 11pm last night I was in denial. There must be a reason why they honed it this way. Maybe it will be fine. How much difference can running some special grease through the bores for a minute actually make?

I woke up feeling regret. Dad always told me that I shouldn’t touch things that weren’t broken. It’s my way to keep going until I’m satisfied. This block should probably have been left as it was. Possibly just new piston rings would have sufficed.
The sandy finish inside the bores before we started the work, is exactly what we are now looking for.

Then came acceptance.
My plan to have the engine built today and possibly in the car over the weekend was out of the window. It dawned on me that I would never be happy to just suck it and see. Even if the engine started up and didn’t smoke, it would bug me every time I saw the car.

This morning I spoke to all of the local engine builders. Out of five calls, only three knew what I was talking about. Only one has ever had the equipment to do it and no longer has it now due to lack of demand.

I spoke to other engine builders further out. After several calls only one company I found still does this work. Not local.

So at 10am this morning I undid all of last night’s work. Removed heads and stripped the block down again. So very frustrating.

Got it loaded and is currently being driven to Engine builder No 3.

My biggest worry now is that this builder will decide there is not enough cylinder left to hone and it needs liners. I don’t want to go down this road if possible.

They say they are very busy and could take up to two weeks to turn around.

Ah well, I guess I now have time to sort out that headlamp wiring.

Thanks again to those who spotted the problem and posted. Very much appreciated. Now where is that voodoo doll.

[video=youtube;Glja_6VanUs]https://www.youtube.com/watch?v=Glja_6VanUs[/video]
 

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My biggest worry now is that this builder will decide there is not enough cylinder left to hone and it needs liners. I don’t want to go down this road if possible.
In general you don't want sleeves... and, I'm not sure if you can get Alusil sleeves for the M119. The factory fix would be to bore 0.5mm oversize and use oversize pistons but that of course is $$$$. Hopefully they will be able to etch the block and still have everything within spec! Sorry you are running into this snag...

:hiding:
 
We looked into oversize pistons and they arent available. They would have to be custom made. I was told there wasnt enough wear to worry about it so we left it. I dont know what will happen after this honing process though.
 
Chris is doing some more today.

He is spot welding slowly and then griding back. Spott welding some more and then grinding back… Repeat until the join is totally smooth.

He is not risking one continuous weld as the heat will distort the panel.

I stripped the intake manifold down to its component parts and replaced all gaskets, seals etc. Gave it a clean out too.

Replaced all injector seals, vacuum hoses and rubber breather hoses. Its much easier to do whilst its out.
 

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Thanks all. I welcome all comments and suggestions. Many of you are far more knowledgable when it comes to the details of this model than I...
 
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