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Thread: W124 500TE Project - Lets do this!

  1. #61
    Senior Member jaymanek's Avatar
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    Re: W124 500TE Project - Lets do this!

    Hi All,

    I dont think this engine wants to go back in the car. I have another slight set back.

    I installed the new chain, guides etc. Turned the engine by hand a few times and everything spot on. My 6mm "factory tools" nicely drop into place when crank is at 45 before.

    Then tonight I installed the timing case cover with new O rings and using the usual Mercedes sealant that I keep. This is the stuff recommended for timing covers, its sticky, tacky and never really goes hard.

    Then I installed the oil pump, upper pan and lower pan. I have a question about sealant so will start a thread on that.

    All good.

    I rotate the engine back around on the stand to its normal position and start packing tools away for the night.

    I notice a rubber O ring perched on the camshaft pulley.

    Took me a moment but I realised what happened.... I may have cursed a couple of times.

    So now I need to undo all that work. This is not the problem. The problem is I have to wait for new sump gaskets from Mercedes which im sure will be a 2-3 day order.

    GRRRRR.

    Yes, yes, im glad I noticed it now rather than once installed, but I think this engine is really trying to get me back for messing with it.

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  3. #62
    Senior Member jaymanek's Avatar
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    Re: W124 500TE Project - Lets do this!

    Spot the difference:

    Just gotta laugh.
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  5. #63
    .036 Hoonigan™
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    Re: W124 500TE Project - Lets do this!

    Oooo! I found it! I found it!

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  7. #64
    Senior Member jaymanek's Avatar
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    Re: W124 500TE Project - Lets do this!

    there are more... ill give you a clue. i only noticed when trying to bolt in the timing case cover.

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  9. #65
    E500E Guru JC220's Avatar
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    Re: W124 500TE Project - Lets do this!

    Quote Originally Posted by jaymanek View Post
    there are more... ill give you a clue. i only noticed when trying to bolt in the timing case cover.
    Yes that's a biggie! The bolt holes don't match up. Are there different gasket PN's available? Could it be you have one from a earlier or later m119? Gen-U-Whine gaskets yes?
    1987 w124 200 E36 AMG Project car - ongoing 1990 w124 300E-24 Fully Restored
    1992 w124 500E Rolling Restoration - ongoing 1994 C124 E320 - Recently acquired resto project
    2007 w211 E220CDI Avantgarde Daily Driver
    Parted out myself- 95 C36 AMG / 95 E250D / 98 w124 India E220

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  11. #66
    Senior Member jaymanek's Avatar
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    Re: W124 500TE Project - Lets do this!

    Its my fault.

    There are two gasket versions for the left. Early or Late.

    I ordered early gaskets for both sides as everything for this car is the early version.

    On the right head gasket there are three choices and I didnt notice that mine is the "middle" version.

    5 day order from Germany.

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  13. #67
    E500E Guru JC220's Avatar
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    Re: W124 500TE Project - Lets do this!

    Yes I see that - yours should be 1190161820 for the left & 1190161920 for the right by my reckoning
    1987 w124 200 E36 AMG Project car - ongoing 1990 w124 300E-24 Fully Restored
    1992 w124 500E Rolling Restoration - ongoing 1994 C124 E320 - Recently acquired resto project
    2007 w211 E220CDI Avantgarde Daily Driver
    Parted out myself- 95 C36 AMG / 95 E250D / 98 w124 India E220

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  15. #68
    Senior Member jaymanek's Avatar
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    Re: W124 500TE Project - Lets do this!

    I know.. Had these gaskets here for months now too.

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  17. #69
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    Re: W124 500TE Project - Lets do this!

    Quote Originally Posted by jaymanek View Post
    I know.. Had these gaskets here for months now too.
    It happens to the best of us! I have shelves filled with parts that didn’t fit and too late to return.... The engine cylinders look great now BTW – it’s coming together nicely! Great work. Do you intend to fully respray the car? Or blend the paint if the rest of it is still decent?
    1987 w124 200 E36 AMG Project car - ongoing 1990 w124 300E-24 Fully Restored
    1992 w124 500E Rolling Restoration - ongoing 1994 C124 E320 - Recently acquired resto project
    2007 w211 E220CDI Avantgarde Daily Driver
    Parted out myself- 95 C36 AMG / 95 E250D / 98 w124 India E220

  18. #70
    Senior Member jaymanek's Avatar
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    Re: W124 500TE Project - Lets do this!

    The whole car is being painted including the door shuts.

    The loose plan was to get the engine in and running in the next week or two.

    The bodyshop say they can work on the paint over the Christmas period which is normally quiet for them.

    However it seems like I am having to do everything twice at the moment so we will see how that plan goes!

    I certainly do not want to paint the car until the engine is in and running.

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  20. #71
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    Re: W124 500TE Project - Lets do this!

    I completely missed the timing cover bolt pattern.

    This also solves the mystery as to why the right cylinder head, gasket, AND timing cover are all different for .974 engines up to #1893.

    Affected engines would have been very early builds, 1990-1991 and very, very early 1992 USA model year. The change would have been approximately in September 1991.


  21. #72
    Senior Member jaymanek's Avatar
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    Re: W124 500TE Project - Lets do this!

    Mine is engine no 5037.

  22. #73
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    Re: W124 500TE Project - Lets do this!

    Quote Originally Posted by jaymanek View Post
    Mine is engine no 5037.
    Small world. One of my engines is 5031, only six away from yours! And yep, it's the "middle" range.

    The late gaskets were for the switch to open-deck blocks (early/mid 1994 production dates).


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  24. #74
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    Re: W124 500TE Project - Lets do this!

    Well we live and learn... This is my first M119 full rebuild and it is turning out to be an education.

    Done a few M117's and lots of smaller MB engines before...

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  26. #75
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    Re: W124 500TE Project - Lets do this!

    This was the engine when I was timing it up. I then had to pull the right head gasket back off so now its all off again.

    Question:

    The freewheel pulley that wedges between the timing cover and block. Any special grease recommended here? I find it odd that there is no special surface here for the pulley to spin on.
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  28. #76
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    Re: W124 500TE Project - Lets do this!

    You mean the center chain drive sprocket? It is lubricated by oil pressure, supplied by a bore in the block directly to the main oil galley (direct below the sprocket in your photo) flowing through the hollow shaft and then reaching the outer flange to lubricate.
    Last edited by Rouven036; 4 Days Ago at 02:39 PM.
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  30. #77
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    Re: W124 500TE Project - Lets do this!

    Yay the head gasket has arrived! So today spent some time and put the head back on.

    Then I resealed the timing case cover with the correct orange sealant, part number A0019898920/10.

    Once this was on I reinstalled the oil pump, oil level sensor and finally the bottom sump.

    There is debate on whether to use sealant with the paper gasket here or not. I decided to go with the Mercedes instructions and went with a thin layer at the back end of the block.

    Mercedes specify their own clear RTV sealant here A0029894520. Expensive stuff it its just regular RTV.

    P.s. I over ordered loads of both of the above sealants. If anyone wants any at trade price, I’ll be happy to sell.

    Once both the timing case and bottom pans were on, I could go about setting the timing.

    I had to remove the right camshaft adjuster mechanism in order to be able to fit one of the head bolts that goes into timing chain. I wish I hadn’t have done this. It was a pig to get back together again due the tension in the spring.

    In hindsight I should have just removed the camshaft altogether, put the bolt in and refit the camshaft complete.

    Anyway, all done and set up the timing. Pushed around 8 turns of the engine and the factory 6mm pins have dropped into their holes each time.

    Note the old water pump was just fitted temporarily for the timing marker fitted to it.

    New water pump and ancillaries to be fitted next.
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  32. #78
    Senior Member jaymanek's Avatar
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    Re: W124 500TE Project - Lets do this!

    Hi All,

    Today was about getting the engine built up.



    This is the factory tool to get the crank seal in exactly the right place. (Thanks 500E forum).
    I used the “deeper” setting of the two.


    These are all the parts I was hoping to get fitted today. Didn’t get all done but not much left.




    That’s it for today folks. Im tired!


    Question:

    The orange goo doesnt seem to be going off at all.. Im just testing the little bits that have squeezed out and still seems very fluid. Its been over a day. ?? Normal?

    If anyone spots anything I am doing wrong, please say!

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  34. #79
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    Re: W124 500TE Project - Lets do this!

    Looks GREAT! I can't tell if your serpentine belt tensioner is new or used, but if it's used and appears rather old, I'd consider replacing it. Make sure the washer behind it is in the proper position (I always forget which way is correct, in front of or behind the tensioner lever).

    Also - for the air/smog pump bracket, if you didn't coat the bolt threads with the orange anaerobic sealant, pull those out and coat them as shown in the attached photo. Otherwise you end up with a small oil leak that's nearly impossible to track down.

    Oh, and yes, it's normal for the orange goo to remain gooey. It only dries / seals in the absence of air, so any exposed squeezeout will not dry up. This has a side-effect of ensuring no blobs of dried sealant fall off inside the engine to clog oil passages. I suspect it's one of the reasons MB used this stuff.

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  36. #80
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    W124 500TE Project - Lets do this!

    Fantastic that’s the kind of tips I need.. I will coat those threads..

    The tensioner is original. However the mercedes part was very expensive. I couldnt find any good aftermarket tensioners so decided to leave it.

    Any brands aftermarket that can be trusted?

  37. #81
    Senior Member jaymanek's Avatar
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    Re: W124 500TE Project - Lets do this!

    Oh and I found that the lower harness was much worse than i thought. I can’t understand how the car ran.. so tomorrow I will spend some time and replace the wires. Same with wiring at AC pump.. it will have to suffice until MB supply them again..

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