DIY Restoration: 1980s Mercedes G-Wagon Engine & Fuel System Revival

Rescuing the Abandoned G-Wagon

• 🎯 The video chronicles the rescue and restoration of an abandoned 1980s Mercedes G-Wagon, chosen for its Recaro seats and manual transmission.
• 💡 The G-Wagon, a vehicle originally designed as a military vehicle, has become a popular choice for daily driving without off-roading.

Engine Health and Initial Startup

• 🛠️ After 10+ years of sitting, the dual overhead cam straight-six engine was revived by spraying a "magical concoction" into the cylinders, allowing it to spin by hand.
• ⚡ A charged battery enabled the engine to crank and, with a makeshift external fuel system, to run and produce minimal smoke.
• 🔍 Inspection of the engine's top end revealed perfect cam lobes, dual roller timing chain with mint guides, and a unique water drainage system in the cylinder head.

Fuel System Overhaul

• ⛽ The original Bosch CIS fuel injection system, notorious for issues after long periods of disuse, required a complete overhaul.
• 🚧 The existing fuel system was found to have an excessive number of filters and questionable modifications, prompting a decision to rebuild it from scratch.
• 💧 The fuel tank was drained, revealing old, green, varnish-like fuel that was surprisingly still flammable.
• ⚙️ A new fuel pump, pre-filter, and main filter were installed, along with new fuel hoses and push-lock fittings for a reliable system.

Cooling System and Ancillaries

• 🧊 The coolant was flushed and replaced with period-correct green coolant, despite the system appearing relatively clean.
• 🌡️ The thermostat housing was removed, and the thermostat was replaced using a seal found from a different Mercedes model.
• 💧 Power steering fluid was checked and found to be in good condition, with the reservoir full.

Injector Cleaning and Final Engine Run

• 🧼 Fuel injectors were removed and cleaned using an ultrasonic cleaner with degreaser after a manual cleaning process.
• 🔥 After reinstallation and a fresh fuel fill, the engine started and ran on its own fuel system, though it initially idled high and misfired.
• ✅ The idle issues and misfires improved as the new fuel and performance improver circulated, indicating the injector cleaning was effective.

Transmission and Next Steps

• ⚙️ A clutch was installed, but the transmission would not engage into gear, presenting a significant challenge for the next video.
• 🏁 Despite the transmission issue, the engine is running exceptionally well, with no smoke and good temperature regulation, setting the stage for transmission, brake, and other system work before the G-Wagon can drive.