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Author Topic: 220 Engine Rebuild  (Read 997 times)

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Offline Scott Montoney

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  • 1952 - 220 Cab B
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  • VIN #: 187.013.04370/52
  • Year_Model: '52 220 Cab B
220 Engine Rebuild
« on: June 18, 2017, 09:16:04 PM »
Well, the time has arrived.
I've had my car for 10 years now and have put over 52,000 km on her.  But the time has come for "Gertrude" to have open heart surgery.
Her #2 cylinder fouls the spark plug with oil and there is no compression.  In addition, there are metal flakes found in the oil filter.
Time to pull the engine and see what is going on.  I've taken apart nearly every other part of this car except inside the engine block. 
The current mileage is in the area of 551,800 km.
I'm not sure of the last time the engine was rebuilt.  I know it was done by the MB factory in Stuttgart in 1963, but I will have to check my records to see if anything has been done since then.  The head was fully rebuilt around 2008.
I'm sure I will have many questions along the way for those of you that have traveled this road already, so check in from time to time as I post pictures and seek information.
Thanks,
Scott
« Last Edit: June 19, 2017, 02:02:25 PM by Scott Montoney »
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline John Ellis

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Re: 220 Engine Rebuild
« Reply #1 on: June 19, 2017, 04:33:15 AM »
Scott, sorry about the situation, but looking forward to your documentation and insight to the process.  Thanks.
John Ellis
1953 170Vb
1958 190
2007 Porsche Cayman

Offline Scott Montoney

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  • VIN #: 187.013.04370/52
  • Year_Model: '52 220 Cab B
Re: 220 Engine Rebuild
« Reply #2 on: July 02, 2017, 11:12:23 PM »
I got to spend some time in the garage this weekend.
Engine is out. Next is to start the investigation inside to see what is going on.
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Scott Montoney

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Re: 220 Engine Rebuild
« Reply #3 on: July 03, 2017, 01:22:54 PM »
Here is a photo of the debris on the oil filter.
And the fouled spark plug.
« Last Edit: July 03, 2017, 01:43:30 PM by Scott Montoney »
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Scott Montoney

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  • VIN #: 187.013.04370/52
  • Year_Model: '52 220 Cab B
Re: 220 Engine Rebuild
« Reply #4 on: July 03, 2017, 01:27:14 PM »
Here is what I have found so far.
I have removed the head and #2 piston.

The photos show that the bottom ring on the piston is coming apart.  It had also started to wear the piston.  I don't know if this means the piston must be replaced or not??
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Scott Montoney

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Re: 220 Engine Rebuild
« Reply #5 on: July 03, 2017, 01:35:57 PM »
Well, apparently the fouling in that cylinder was enough to cause the exhaust valve not to seal properly anymore.
This caused the exhaust gases to burn the valve.
All the others look ok, but I have not removed any of them yet.

« Last Edit: July 03, 2017, 11:32:53 PM by Scott Montoney »
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Charles Adamson

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Re: 220 Engine Rebuild
« Reply #6 on: July 03, 2017, 03:49:51 PM »
Scott,

I say the piston needs replaced. The hole will cause a leak.

Charles Adamson

Offline Scott Montoney

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Re: 220 Engine Rebuild
« Reply #7 on: July 05, 2017, 08:08:54 AM »
Everything is now apart.  Found two more pistons with lesser degree of broken ring issues.  Those pistons are not damaged in the ring groove like the photo I posted earlier.  Although not easily visible to the eye, two of the cylinder walls have an uneven wear pattern that can be felt by hand.

Now starts the investigation as to how to proceed. . . .
What parts MUST be replaced?
What parts should be replaced?
What parts are even available?
Where to have the machine work done?

If I was only driving it on/off a trailer, I might be able to get by with only replacing broken rings.
However, I enjoy driving this car, so I need to make sure it is well suited for extended road travel.
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Charles Adamson

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Re: 220 Engine Rebuild
« Reply #8 on: July 05, 2017, 11:51:50 AM »
Scott,

Check to see if the tolerances apply to your engine according to the workshop manual.

Charles Adamson

Offline Scott Montoney

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Re: 220 Engine Rebuild
« Reply #9 on: July 05, 2017, 02:16:27 PM »
Here are some more photos.
This is showing the collection of debris that had settled in the water jacket behind the two side plates of the engine.

Hmmm.  For some reason, my photo's that are taken with my iPhone in a portrait mode, are showing up sideways in the posting, even after a did an additional 90 rotate to try to compensate.  Oh well, you get the idea.
« Last Edit: July 05, 2017, 02:21:21 PM by Scott Montoney »
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Scott Montoney

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Re: 220 Engine Rebuild
« Reply #10 on: July 05, 2017, 02:44:37 PM »
By the way, my pistons are marked as 80.46.  I believe this is the first oversize piston diameter.
I do have the technical data book and the shop manual.  Will dig into them next "free time" I get.

My worst piston is #2 with the bad slotted oil ring.
One of the other pistons had part of the lip of the ring broken off, and the third piston had a broken compression/top ring.

One more set of pictures.
Several of the pistons had black deposits going down the top edge of the piston.  When I cleaned one up, I saw that the piston was actually deformed under the deposit.  Not sure if this is normal or not.  This happened to be the side of the piston just under the spark plug.
See attached photos.
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Henry Magno

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Re: 220 Engine Rebuild
« Reply #11 on: July 07, 2017, 02:50:36 PM »
I'd say new pistons from the look of it. The oil ring clearance looks huge. You need to keep in mind that pistons with this much abuse will have ring groove wear. Doubtful you could ever clean up bore wear and/or damage with merely honing.

Start looking for some NOS pistons of the next size. Also when you determine what size crank bearings you need, try to find NOS Glyco or other OE bearings. There are new replacements that are not great. It's worth checking ebay and other sources.

Offline Scott Montoney

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Re: 220 Engine Rebuild
« Reply #12 on: July 07, 2017, 03:11:43 PM »
Yes.  I suspect finding parts is going to be a nightmare.
Several years ago I ordered some parts from someone in Germany that was supposed to be NOS, and they clearly were not.  Functional, yes, but not what was advertised.  I haven't checked out any of the crank bushings.  It sounds like you would think it is a safe assumption that they would need replaced as well?
I hope to start creating my shopping list this weekend, then I'll be requesting ideas from this forum.
As always, thanks so much for any input.  This is new territory for me.
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Scott Montoney

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Re: 220 Engine Rebuild
« Reply #13 on: July 09, 2017, 12:48:34 AM »
The Shop Manual shows that the top three rings each have a unique side profile.  See the drawing below.
Here is what my rings look like.  Did they wear so much that the profile is Square now?

The Ring gap is supposed to be 0.30-0.45mm for all three of the top rings.
My top ring had a gap of 2.95mm
Second gap was 1.37mm
Third gap was 0.82mm

I also checked the side clearance in the grove of only the top ring.
Manual says 0.035-0.062mm
Mine is 0.25mm.

Clearly these are all excessive.  I am going to assume the other pistons are in a similar condition.
« Last Edit: July 09, 2017, 01:03:03 AM by Scott Montoney »
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Charles Adamson

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Re: 220 Engine Rebuild
« Reply #14 on: July 09, 2017, 12:17:39 PM »
Scott,

You asked, "Did they (the rings) wear so much that the profile is Square now?"

Perhaps the bore in the block shows wear since the rings move up and down in the bore.

Which material is the hardest? I suspect the rings.

Charles Adamson

Offline Henry Magno

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Re: 220 Engine Rebuild
« Reply #15 on: July 09, 2017, 04:14:03 PM »
When you know your crank bearing sizes, then check around. This will be your hardest part. You can look for pistons or have them made by Venolia or Arias in CA. This is cost effective unless you get a bargain on the pistons. I had 170 pistons made by Arias I think. These are better than original as they are forged.

Check your wrist pin size. If it is still 22mm you should round up some later 24 mm rods, since it's easier to find those pistons. If you are making pistons this won't matter.

Offline Scott Montoney

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Re: 220 Engine Rebuild
« Reply #16 on: July 09, 2017, 09:06:40 PM »
Charles - I'll ask my question a different way.  Since I have never seen a new set of rings, are they still the same as what is shown in the drawing, or is it possible that the style of the rings has changed from what is drawn to what I have in my car?

Henry -  Yes, the pins are 22mm.  You asked about the crank bearing size.  I assume this is the four large bearings and not the rod bearings on the crank??
In either case, the surface on the crank of the large bearings measure about 59.43 mm, and the part number of the current bearings is 1803301 (some have "KZ" as part of the number.  Possibly Mfg.)
Or do I first have to have the crank turned down to a specific size?
The 6 bearings for the rods measure about 47.42mm and the bearing part number is 1804410 "KZ". 

Aa I read through the manual and these entries, I need to ensure the correct sequence of steps.  If the bearings are of a specific thickness, then I assume the crank must be turned down to very specific diameter.

As an example. . . Currently my main bearing journals measure 59.43.  I see in the parts manual there are bearings for 60mm - 59.0mm in 0.25mm increments.  Should I then have mine turned down from 59.43 to 59.25, and then get bearings with the inner diameter of 59.25mm?

Here is one more important point to be aware of.  In 1963, this car was shipped back to Stutgart to have a lot of work done by the factory.
The Shop Manual makes mention of a preferred process of swapping out major components such as engine, transmission, etc.  I think this was done.
I believe that the block and head are of a newer engine and maybe some of the part numbers are not the same??
I see that none of my current bearings for the crank or rod are in the original parts manual.  I also see that the piston is of the 220a style.
So, if I need to start looking for bearings for the crank, should I be looking for the ones with I.D. of 59.25mm? My 220 parts manual shows that part number as 180 033 09 01.
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Scott Montoney

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  • VIN #: 187.013.04370/52
  • Year_Model: '52 220 Cab B
Re: 220 Engine Rebuild
« Reply #17 on: July 09, 2017, 09:10:23 PM »
Henry, another question just came to mind regarding pistons and rings.
If I can find NOS pistons, or more likely, have some made, will they come with rings?

And. . . Can I reuse the rod bolts?  I see they are of a very unique shape. Are they even available?
« Last Edit: July 09, 2017, 09:13:30 PM by Scott Montoney »
"Gertrude" a.k.a. "Troidl"
1952 - 220 Cabriolet B

Offline Charles Adamson

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Re: 220 Engine Rebuild
« Reply #18 on: July 09, 2017, 11:30:34 PM »
Scott,

Here are some videos about piston rings.

https://www.youtube.com/watch?v=y9Dh2K7kAHs

Charles Adamson

Offline Henry Magno

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Re: 220 Engine Rebuild
« Reply #19 on: July 10, 2017, 09:07:36 AM »
On the bearings, usually you can go to the next size, in rare cases if the crank has little wear, the same size. We are talking about both mains and rods. You need your machinist to check this first. Sometimes if you have damage you may need to go two sizes. Don't go by numbers on the bearings. All the crank gear is the same into the sixties, except flywheel and front balancer. New pistons come with rings. Your block is not updated, it was used until 1957.

Have you ever assembled an engine before? It's not trivial.