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W123 Engine Swap - A satisfying weekend

jaymanek

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Nov 29, 2002
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Location
Nuneaton Warwickshire
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Lots of Mercedes!
My 123 was born with the very last of the M115 type engines, same basic engine used across most of the smaller engines across the range from the 60's onwards.
Although very strong, M115 does not like to be tuned and is very heavy on juice..

Some time ago I deided to upgrade to the later 200 engine. kept an eye out on Ebay and around two years ago I spotted an 80,000 mile car with front end damage (bent bumper and bonnet).
Bought that and since then its been sitting on my drive waiting for me to get the courage up to do the transplant.

So I got talking to Mr Ian B Walker at the last get together and we arranged to do it last weekend.

I arranged all the new parts needed in advance, this included a 5 speed gearbox (to replace my 4), gear selectors, clutch, propshaft, Propshaft donuts, engine mounts, leads, plugs, Distributor cap and all the rest of the service items needed..

Mr Walker and two enthusiastic apprentices arrived at around 7.30 on Saturday morning and we wasted no time.

We all worked through the day, no breaks.

By around 11 am we had both engines out of both cars... This was the easy bit!!

The rest of the day was spent refitting all the new parts and lets just say putting things back together is a lot harder than taking them apart!

After a lot of extending of wiring looms and messing with clutch plates and so on we finally had it all together at 9.30pm.

Mr Walker, his son and friend were all fantastic so special thanks to them.

Sunday was spent tidying up, tightening bolts and servicing the new engine... Still a few finishing touches to be made however.

The result is fantastic, with that five speed box and later engine, she's better than new! who knows, might even get more than 10mpg now!


Here are the pics:

Original Engine
1.jpg


New Engine
2.jpg


Work Begins on the donor car

3.jpg


4.jpg


The old motor coming out
5.jpg


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7.jpg


And the new one in!

8.jpg


9.jpg


10.jpg


Facelift Headlamp Mod (Grill Mod to Come!)
11.jpg
 
Wow, what a great tale. Glad you got it all done in just the weekend. What was the replacement engine exactly? It looks like an M103 or 104.
 
Well done guys, like the pics. Sure the job was made easier with access to a ramp and a good engine crane. Possibly in a main dealers it would have taken several days and Mucho Dinero! I'm sure your experience will re-enforce what I said about safety and getting plenty help when you undertake a major bit of mechanicing. A project that can turn into a nightmare alone can be fun with the right kind of help. Nice one!
 
To add my bit. Firstly I have to say that Jays facilities are first class and we would not have completed it in a day if it were not. Nothing was too much trouble and for that I and my "crew" are more than thankfull.

The day started for me at 4am when I got up, looked outside and had an instant panic, snow, lots of it. Picked up son and Dylan and off we went. This is what we drove through on the way down.

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We arrived there at 8am and looked at the task in front of us. Two engines to come out and a gearbox. I had spent the week planning how to do this but when we were there changed it. My intention was to remove the engine and gearbox, as a unit, out of the good car. Upon looking at it it was decided to remove the engine then the gearbox. But first, a trial. The donor car was put on the ramp and the engine removed in about 45 mins. Very easy engine to work on, unlike the 201 / 124 series as you could get at the bell housing bolts. Oh damn, we sheared off two exhaust downpipe bolts. So armed with a drill it was a, lay on your side and drill them out. Next was the good car. Once again, engine and then gearbox. another hour was spent on doing it. Ok now to replace everything. Remove exhaust. Remove the prop shaft and modify, replace the doughnuts (makes sense really as its already out). Fit new clutch to new engine. (no mandrel). Fit new gearbox and connect to prop shaft. (Big mistake) Offer engine to gearbox and it wouldnt go. Lots of head scratching later we removed the gearbox and checked the center of the clutch, it was a mile out. We needed a mandrel. With an angle grinder we cut off the old gearbox input shaft and used that. Mounted the engine and offered up the gearbox, Bingo, in it slid. Connected up everything and went to bleed the clutch. I now know why most Mercs are automatic :rolleyes: Cutting a long story short and after some ingenious wireing up from Jay the beast ran. Point to note though. The original engine was only held in by one engine mounting :crazy: The car had previously been inspected at a well known Indie and passed as sound. Please do not ask for the name as I am not going to post it. We finished the task at 9pm and after a hasty goodbye set off for home and a well earned kip. Once again I would like to thank Jay for his hospitality, equipment and humour. I would also like to thank Christopher (my son) and Dylan for their outstanding help, without EVERYONES help this would have taken days not hours.
 
Sp!ke said:
Wow, what a great tale. Glad you got it all done in just the weekend. What was the replacement engine exactly? It looks like an M103 or 104.

Its actually a 102... The donor car had full MB history, right up to the accident... It shows as it runs perfect.. and should run even better when i figure out the 'non essential' wiring for the carbs etc..

Car feels so much smoother and cruises along the motorway now, 5th gear really makes all the difference..

As for the equipment, im lucky to have a dad who owns a Service Station/ Garage!

Original plan was to do it on my drive at home - Glad we didnt do this, we would never ever have got close to finishing!

On the to do list: Sort out wiring, New Gearknob, Powder coat Air Box & Rocker Cover, Change Grill and I think im done for a while...

Feeling very poor now!!
 
Nice job there people. Although I have to say I don't envy you, it must have been bloody cold on the old fingers!!!!

I had an old w123/200 ('85 Model), although with the 4 speed box (Man). Did thousands of miles traveling around Southern Africa, never gave me any problem, which was nice, because you sure as hell didn't want to break down in some of those places!!!

Cheers, & good luck.
:)
 
I was wrong. Turns out there are some interesting things you can do in Coventry! :D

PJ
 
erm no, you were right, interesting things only happen in Nuneaton... I maintain Coventry is an ugly concrete jungle...
 
That's a good days work Guys and a nice mod for an old car. Well done all.
 
Thread rated. What an excellent write up, well kept secret until post event and fantastic generosity from Ian.
 
Well done to you all - Fantastic achievement and team effort all done in a day as well... :)

PS. Ian - cigarettes and engines dont go well together... ;)
 
Well done guys. It's the true spirit of the MBClub shining through. Helping each other out, and going the extra mile to do something a little different.
 
jaymanek said:
Especially when theres petrol pouring out of the pipes!

Nah, you could put your fag out in it.
 

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