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  #1  
Old 12-16-2011, 12:04 PM
rapidoxidationman rapidoxidationman is online now
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Default LLY head gasket & water pump swap play by play

anybody interested?

I ordered the parts from Kennedy today and will be embarking on this big project probably just after Christmas. Assuming that I do it right and successfully I can put together a picture thread on how I did it if there's any interest on it...
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'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

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  #2  
Old 12-16-2011, 12:41 PM
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That would be great. We can't have enough hands-on documentation. Let me know if you need any assistance getting it posted.
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  #3  
Old 12-16-2011, 05:56 PM
NutNbutGMC NutNbutGMC is offline
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Quote:
Originally Posted by rapidoxidationman View Post
anybody interested?

I ordered the parts from Kennedy today and will be embarking on this big project probably just after Christmas. Assuming that I do it right and successfully I can put together a picture thread on how I did it if there's any interest on it...
Excellent.
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  #4  
Old 12-28-2011, 09:15 PM
rapidoxidationman rapidoxidationman is online now
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Default It begins.

The parts from Kennedy should be here tomorrow afternoon. I spent today under the hood of my truck tearing things down...

Started with a clean slate:

Yup, it is a bit intimidating to this rookie. I'm gonna just take small bites and eat the whole thing...
I started with removing both batteries. Not necessary perhaps, but a simple thing to do that got me off on the right foot. The cross brace at the front left of the truck (over the LH battery) came off too. Now there's a spot to put tools while I work
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'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #5  
Old 12-28-2011, 09:24 PM
rapidoxidationman rapidoxidationman is online now
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Next to go was the air box and turbo inlet tube, another easy step:


took a couple pics of the Bosch EDU wiring harness to get me through the reassembly, then turned my wrenches to the charged air cooler outlet ductwork from the intake manifold tube:

Note that one can simply unclip the zip tie that holds the wiring harness cover to the inlet pipe. I cut mine before I noticed. Oops. No biggie, they're making new zip ties every day. Loosen and remove the wiring harness from that piece of ductwork.
Then I removed the wiring harness from the Bosch EDU on the right side of the engine.

from a couple of places.


I also pulled the wiring harness from the base of the intake manifold ductwork:


Now I was able to remove that intake manifold tube by removing 2 bolts and 4 nuts. The gaskets (2 rectangular and 1 round) came out easily and will be cleaned up for reuse.
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #6  
Old 12-28-2011, 09:37 PM
rapidoxidationman rapidoxidationman is online now
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Removing the serpentine belt was another easy task, and is what I did next. The sound of the two idler pulleys tells me it is time to order up a couple of them cuz I don't care to have a bearing spin out on me sometime soon. They're on the list for the parts store.

Next out is the alternator. Easy to remove, but it did take a bit of careful prying to get it out of the bracket it is clamped to. Patience was key to not wrecking something expensive. The wiring harness got taped and labelled, just like every other wire in the snakepit that is this truck's electrical harness.

The AC compressor was next. 4 bolts from the bracket and it was loose, and removing the batteries gave me the ideal spot to store it without disconnecting any of the charged hoses: the right battery tray. Easy peasy and it folded right into place.
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'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #7  
Old 12-28-2011, 09:49 PM
rapidoxidationman rapidoxidationman is online now
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Time to turn my attention to the front: remove the ecu/tcm from the left side of the radiator shroud. Two bolts at the top and lift it out, disconnect the wiring harness from the very expensive boxes contained therein. After the electronics were out of the way, I removed the other two bolts on the top lip of the shroud then unbuttoned the removeable rivets from the mdsection (two per side). Pry up the center button and the whole rivet can be removed then reused on reassembly. No pics, but it's pretty self explanatory.

Time to drain the cooling system... removed the lower splash shield beneath the truck, donned my safety goggles, and loosened the clamp on the hose where it connects to the water pump inlet (inlet? I think so, but correct me if I'm wrong...), set a large pan beneath, and pulled the hose loose. Caught most of it, but mopped up a bit. Now I was able to remove the upper radiator hose between the radiator and the thermostat housing outlet (inlet?) tube.

Question for the experts: which way does coolant flow? Does it go into the radiator from the top or bottom?
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #8  
Old 12-28-2011, 10:10 PM
rapidoxidationman rapidoxidationman is online now
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Time to jump into the wiring snake pit again...
disconnect the two wiring superconnectors on the bracket that lives behind the AC compressor:

Great design, fold the handle back and it pushes the connection apart. Clever bit of engineering. In the pic, one is engaged and the other is disengaged. I also disconnected the wire from the box at the rear of the engine compartment (glow plug relay, I think?) so I could move the wiring harness out of the way:

Don't forget to keep labelling your wires as you remove them...

Now the power steering pump is being removed from its bracket. Left the hoses connected and pulled the pump out of the way with some bailing wire.

The battery terminal station that is mounted to the PS pump bracket can come with it. I removed mine before I realized that.

Removing the fan/clutch assembly without access to the proper tools can be tough. Fortunately I'm at a shop that has pneumatic tools... installing it with the proper amount of torque is going to be tricky though.

Then I removed the wiring harness from the bracket on top of the thermostat housing:

Then the superconnector mounting bracket that holds the 2 superconnectors previously disconnected had to come out.

There's a couple more connections that go to the turbo (modulator?) that need to be disconnected and labeled.

The turbo black box that's connected to the turbo via a white wire needs to be removed from the bracket and moved out of the way (I left the other end connected to the turbo).


which put the EGR crossover tube in the way. Time for it to go. A bolt on either end, loosen the clamp on the intake manifold pipe, and gently pull it out at the T shown here
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'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #9  
Old 12-28-2011, 10:20 PM
rapidoxidationman rapidoxidationman is online now
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Yup, lots of jumping around the engine bay by this shade tree mechanic. Now I pulled the turbo coolant inlet (outlet?) pipe from the thermostat inlet (outlet?) housing pipe. This was a bit tricky, but I was able to turn the part seen in the pic with the number 5 on it loose by holding the clamp on the rubber hose open so the hardware would spin.

Now I was able to get the thermostat housing cap out with the thermostats and the outlet (inlet?) housing pipe. Next out was the oil filler pipe:

Next the power steering and AC compressor bracket needed to go. Easy enough:

and on the other side, the serpentine belt tension pulley needed to go:

and in order to get the alternator bracket out, a few other steps had to be made...
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #10  
Old 12-28-2011, 10:39 PM
rapidoxidationman rapidoxidationman is online now
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beginning with removing the charged air return line from the intercooler flex hose:

and removing the heater coolant outlet (inlet?) pipe at the top:

and the bottom:

finally I was able to remove the Bosch EDU (2 fuel lines, 3 bolts - don't lose the bolt bushings...)

pay close attention to all the wiring harness mounts...
and now the alternator mount bracket can come off, with the two idler pulleys still mounted. Not that a fuel line is mounted on a bracket extension and the oil dipstick tube also needs to be disconnected from that extention.


back to center: Disconnect the temp sensor wire on the thermostat housing:

remove the turbo inlet elbow

remove the turbo servo wire and wire bracket
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #11  
Old 12-28-2011, 10:54 PM
rapidoxidationman rapidoxidationman is online now
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then the intake manifold elbow can get pulled out; it is held in the center piece of the intake manifold by an o-ring:

with all that stuff out of the way I was then able to remove the EGR coolant intake tube from the thermostat housing

and the EGR cooler tube (proper name?), noting the odd orientation of the clamps on the cooler tube end of the intake tube:


Now I could remove the fuel line clamp from the thermostat housing

then remove the thermostat housing crossover and the water pump outlet tube.

The little bypass tube from the water pump outlet tube
made things a bit tough

but taking small bites let me eat it all.
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #12  
Old 12-28-2011, 10:57 PM
rapidoxidationman rapidoxidationman is online now
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The last thing I did today was to remove the heat shield from the turbo.

3 bolts got it loose, but I had to disconnect an oil supply pipe and a pipe bracket to make room to remove it:


End of day one, 7.5 hours in.
Time for bed and dreams of torque wrenches, wiring harnesses and the nightmare of plumbing that awaits me tomorrow...

Cheers!
Guy
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'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #13  
Old 12-29-2011, 08:02 PM
rapidoxidationman rapidoxidationman is online now
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Default It's tomorrow. Time for another pile of pics.

but first, jack up the front of the truck, drop it onto some strong jackstands, and remove the front wheels. Gotta get the fender plastics out of the way, and to do that you need to remove the expansion tank:
Note the tubes and wiring harness.

once the tank is out, you can see a couple other wiring harness clips that need to be disengaged before the fender plastic can be removed:

once the plastic is clear, it is a simple matter of removing the push rivets. Most of them have a center button that can be pulled loose to allow the whole rivet to come out. I had a tough time with the big ones, like the one that holds the bottom bracket of the battery tray to the plastic. More stuff for the parts list.
Moving on to the left side: there's more stuff attached to the plastic, but it's straightforward enough.
Next up I removed the fuel filter bracket and fuel lines. A new fuel filter is in the box that I just got today from JK

After that hardware was out of the way, it was easy to remove the A/C evaporator harness and pull a large mess of wires to the left side of the engine bay.
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #14  
Old 12-29-2011, 08:11 PM
rapidoxidationman rapidoxidationman is online now
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After pulling loose the harness from the right side fuel rail sensor

it was time to disconnect the right side glow plug wires

and the injector wires

fairly easy, just take the time necessary to do it right.
After that, the wiring harness clamps can be removed from the engine.

Then I pulled a couple of plugs from 9 o'clock and 11 o'clock by the crankshaft pulley
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'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #15  
Old 12-29-2011, 08:23 PM
rapidoxidationman rapidoxidationman is online now
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Then to the top again: Removed the heater hose from the EGR cooler

then fight the bolts on the backside of the EGR cooler (and the remaining one on the front)

to remove the cooler.
Then I removed the wiring harness from the high pressure fuel pump


and moved to the left side of the engine to remove the glow plug wires

and injector harness and wiring harness clamps, just like the right side but with more wires in the way...

The rear injector harness is kinda buried, but it is accessible with patience.
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #16  
Old 12-29-2011, 08:41 PM
rapidoxidationman rapidoxidationman is online now
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I then removed the glow plug controller harness

and a bracket that holds the wiring harness for the #7 injector and glow plug...

note that the harness lines go UNDER the fuel lines... which are next in line for disassembly:
taking the bracket loose

and disconnecting the quick connect lines: a piece of spring steel clip is the anchor for the coupling, but you need a fuel line disconnect tool (harbor freight $9) to get the lines to separate.

Then I removed the plug on the fuel sensor under the turbo outlet (connects to the left side fuel rail):

then I pushed loose the wiring harness clamp at the fuel line bracket by the turbo outlet
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #17  
Old 12-29-2011, 08:43 PM
rapidoxidationman rapidoxidationman is online now
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removing the sensor wire from the left side intake manifold was next

Note that the wire routes under a fuel line.

I then removed the plug from an unknown harness that goes down the front of the engine to somewhere underneath. I call it "unknown".


I was then able to unbolt the main harness bracket from the center piece of the intake manifold


remove two ground wires from the lower right side of the engine block

and remove that whole wiring harness assembly from the engine bay.
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #18  
Old 12-29-2011, 08:44 PM
rapidoxidationman rapidoxidationman is online now
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Hey look! There's an engine under there!!!


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'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #19  
Old 12-29-2011, 08:54 PM
rapidoxidationman rapidoxidationman is online now
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Time to remove the glow plug controller


Moving on to the plumbing:
remove the fuel main line crossover pipe (2 nuts, 1 bolt for 3 clamps), this pic is of the clamp on the right end of the pipe:


now for some plumbing assembly removal: the fuel supply from the filter and return lines to the HPFP and from the injectors of the right bank of cylinders:

this pic is of the twin pipes on one end, the injector return lines are on the other end. The injector return lines come loose easily by removing the wire clips and gently pulling the plastic fittings out.
__________________
'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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  #20  
Old 12-29-2011, 09:04 PM
rapidoxidationman rapidoxidationman is online now
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then I removed the fuel rails crossover pipe

and the HPFP high pressure pipe to the left side fuel rail:


Then I removed the left and right side exhaust manifold heat shields, 4 bolts each and easy to do.

My last task of the day was to remove the left side injector return lines

and fuel rail return line to the HPFP. This was tricky because there are some bolts under the glow plug controller bracket that are hard to get to with the turbo in place.

Anybody know how to remove the turbo without taking the whole darn exhaust system apart? I'm all ears... and done for today.
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'85 Mercedes Benz 300D, for when I want to be stately.
'05 Mercedes E320 CDI, for when I want to be even statelier.
'05 Chevy K2500 ext cab long box DMax: Everything my '03 was and so much more!

There's no point being a pessimist - it wouldn't work anyway.
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