M103 R&R: Head gasket, timing chain rails, intake manifold

[John5788]

went crazy with a head gasket repair job on the 190E. here are some clean pictures.

Engine disassembled




Cylinder head. 2 angle valve job, new intake/exhaust valve guides, new valve stem seals, hot tank, bead blast, resurface, reassemble.




New head gasket



Head seated on block



New timing chain guide and tensioner rails



Front timing cover hot tanked and bead blasted and resealed, installed





alternator bracket hot tanked and bead blasted




torquing down the cylinder head




sealing top timing cover and cam seal










valve cover bead blasted and powder coated





intake manifold hot tanked, bead blasted



CIS installed



Finished product

[cvjohn69]

looks really good, was it hard?? i plan on doing this to

[John5788]

not hard, just lots of things to do.

[veedubfreak86]

nice work i have always had respect for your attention to detail and documentation of your car thanks again looks great

[JamesDean]

excellent work sir. Stellar job.

[16V4NRBRGR]

There's about a million words worth of photos there, great job.

[scottx]

Like I said in the other thread, you did a great job.

Wheres your wiper fluid tank at?

[John5788]

I took it out, didn't like it.

the engine compression test results came out great.

1: 175 psi
2: 180 psi
3: 180 psi
4: 180 psi
5: 180 psi
6: 175 psi

Tested at normal op temperature with allowed 10 compression strokes per cylinder and all spark plugs removed.

Before the job I was averaging 145psi across first 3 or 4 cylinders and gradually decreasing near 125psi at cylinder 6

[scottx]

Very nice.

[benz190vault]

So clean :)

[Jtn190d]

How much did it all cost? What paint is that?

[John5788]

somewhere around $1k probably, it was alot of stuff. I have a partial shopping list I used to keep track of what I needed to buy in terms of parts

Wiring Harness:

103 159 0213 - Bottom cover
103 159 0113 - Top cover
N000125006449 - Washer 3x
N000912006066 - Screw 3x

Cylinder Head:

103 010 5320 -  Head gasket kit
102 990 0810 - Cylinder head bolts 14x
008 542 3217 - Coolant  temperature sensor CIS
005 542 2617 - Coolant temperature sensor  cluster
008 542 4517 - AC Switch
N007603014100 - Washer for 3 sensors
103 016 0421 - Valve  cover gasket
103 050 0158 - Valve stem seals
103 050 2224 - Valve guide  intake 6x
103 050 2724 - Valve guide exhaust 6x
120 142  0072 - Exhaust manifold nut 12x
111 990 0405 - Exhaust manifold  studs 12x
103 203 0082 - Cylinder Head to Thermostat Hose
012 997  5148 - Seal ring for Cylinder Head Metal Piping 2x

124 500 1749 - Coolant reservoir


111 997 0330 - Oil drain plug
N007603014106 - Washer to oil  drain plug
015 997 3948 - Big seal ring to level sender
017 997 5848 - Small seal ring to level sender
124 542 0017  - Oil Level sender

Timing chain rails:

103 052 0816 -  Timing chain rail outer
103 052 0716 - Timing chain rail inner
120 997 0346 - Front oil seal
N000000001147 - 5mm allen to  timing cover
003 989 98 2010 - Loctite 5900
103 050 0316 -  Timing chain tensioner rail

Intake manifold:

103 141 0090 - Throttle body boot
102 141 3280 - Throttle body to intake manifold gasket
103 094 1382 - Air meter to IACV hose
102 094 0212 - Air duct to IACV hose connector
004 997 0648 - Fuel distributor seal ring

Engine mounts
 
124 240 1917 - Engine mounts 2x
201 990 0912 - Engine mount to frame bolt 2x (bottom)
N304017010038 - Engine support to engine mount bolt 2x (top)

104 200 0528 - Fan clutch bracket

valve cover is not paint, it is powder coated

[Twigmaster]

Did you bead blast the cylinder head or did you pay a shop to do it?

[John5788]

freeway auto supply machine shop did the bead blasting for me

[mike919]

Looks good, cant wait to undergo this project hopefully sometime this summer.


mine burns more oil than gas.

[scottx]

Originally Posted by mike919

mine burns more oil than gas.

Mine burns oil also, not that much but enough to annoy me. It doesn't leak any. I figure it's the rings and valve stem seals.

[John5788]

my oil leaks were coming from front timing cover (no sign of sealant applied on metal to metal surface contact points), front crank seal, and exhaust valve guides.

[202brabus]

That MB sealant is good shit, I got TONS of it. If anyone needs any PM me.

[Twigmaster]

Originally Posted by John5788

freeway auto supply machine shop did the bead blasting for me

Huh... They fucked my shit up so bad I had to get a another head...

[John5788]

ive had no problem with them. they do alot of small projects for me and always comes back perfect.