my W201 shell is getting a OM616 heart and I have questions. - PeachParts Mercedes-Benz Forum

2.5-10 · #1 03-27-2010, 12:17 AM

I have a spare, recently rebuilt OM616 with a 4gang manual attached to it and I also, just happen to have a 1988 190E 2.3 shell sitting behind my shop, my question is:

this is the side of the 616:

-what do I need to connect to what?
-which fuel line is input and which one is return
-should I remove the fuel pump from the car as it was a petrol car before?
-there are two lines coming from around the oil filter, what are the for? pretty thick black hose.

thats all I have for now actually.

layback40 · #2 03-27-2010, 12:59 AM

The fuel supply is the line that goes to the little plastic filter.
The return is that metal tube up by the dip stick.
You dont need the electric petrol pump, the motor has its own primary pump.
Those 2 thick black hoses may be for an oil cooler.
You need to have a diesel ignition switch with the vac shutoff for the injector pump, that yellow hose at the back of the IP I think.
You will have to make the engine mounts fit. I dont know if the sump clears everything.
The 616 may be a bit heavier than the old gasser but with a bit of luck the lighter manual trans may make up for it.
Dont know how the tail shaft will go connecting to the trans.
Diesels dont like gasser mufflers, they need straight through mufflers.
Hope that helps.
Good Luck!!!!

2.5-10 · #3 03-27-2010, 01:05 AM

cool

I am not worried about custom mounts for the engine or trans, and I can cut and weld the subframe to make the pan clear

I have no exhaust for either the petrol or diesel car anymore, so no worries

not really worried about weight, the 2.3 rode like a truck before hand anyway, haha.

I cant seem to find the oil cooler on the 240D, can I use an auto trans cooler in place or should I just order an after market cooler and install?

looking forward to getting my über efficient errand car up and running!

thanks for your help!

layback40 · #4 03-27-2010, 03:29 AM

Can you put up a pic of the black lines so that we can be sure?
If it is the cooler lines, then the best thing would be to go get a cooler off a w123 240 or 300D at a junk yard or clunker. Some on here have made new lines out of hydraulic hose, you need to weld the cooler fittings on to the hydraulic fittings though.

2.5-10 · #5 03-27-2010, 04:27 PM

here:

they do look pretty thick like they are capable of holding 4 or 5 bar.. I wonder what the best solution is for the lines.. would a W123 240 or 300D have the same fittings on the engine to make it easy to remove?

thanks

layback40 · #6 03-27-2010, 09:04 PM

They look like they are a smaller diameter than the ones on a 617. Given you are going to use the car as a run about and not planning on using it to tow a heavy trailer from east to west, maybe a trans cooler would do the job. I dont think all 616 motors had oil coolers. I would be having a look at a 123 in a junk yard. The oil cooler on them is next to the radiator.

2.5-10 · #7 03-27-2010, 10:08 PM

really? I still have my 240d -- don't really see what it was connected to... I see the cooler on the side of the radiator but it was never connected to this.... I don't really know where to look.

any ideas?

also, the 190E only weighs like 2,800lbs so I'm not really worried about the oil getting too hot, but I do want to make sure its ready to be driven hard so an oil cooler is a must

may install a trailer hitch at some point, bought this car for $250 its pretty darn nice and this motor is free to me, so a utility vehicle it shall be!

2.5-10 · #8 03-27-2010, 11:34 PM

the W115 glow plug system doesn't have a pre glow relay it just has a gorilla knob you pull for 15-30 seconds to warm up the plugs, can I just buy an off-the-shelf MB relay and wire it in somehow? I really want to be able to use the 2.3 ignition so I dont have to carry two keys.

as far as the alternator, do I just wire the hot wire to the +12v block on the strut tower, what all needs to be attached to what for that?

the rest looks pretty self explanatory but a 2nd set of eyes is always helpful!

2.5-10 · #9 03-27-2010, 11:35 PM

some pics:

pan clearance looks totally fine.

like my improvised throttle cable? eh? eh?

the 4-speed trans looks good, linkages should end up working just fine

took off the A/C compressor, finally. what a useless piece of crap that was. lost over 40 lbs too!

the W115's shifter bolted right in! wow. not pretty but it'll get the job done!

vstech · #10 03-27-2010, 11:51 PM

beware, the oil pressure on the cooler lines is pretty high. on the order of 8 bar... 120psi not good for hose clamps!!! get those fittings off, and have a set of hoses built at napa or an aeroquip shop... with high pressure connections.

layback40 · #11 03-27-2010, 11:56 PM

you need to wire the small connector on the alt to the idiot light (ig light) the main connector just goes to +12v like you said.

Those black hoses need to be piped to the cooler.

I couldnt see the power steering hoses any place.

You need a good strong relay for the glow, it is best set up through a push button that you hold in until it starts. You dont leave the GP's on once it starts.

You need a vac switch to turn off the motor. it is normally part of the ignition switch. It needs to turn off the vac to the IP stop when the ignition is turned on and turn the vac on when the ignition is turned off. You may be able to find a suitable elec/vac switch controller off the pollution control of something. it needs to be normally open, power to close & vent the outlet. The alternate would be to rig up a kill knob with a cable, attached to the shut off leaver on the IP.

2.5-10 · #12 03-28-2010, 12:21 AM

Quote:

Originally Posted by vstech

beware, the oil pressure on the cooler lines is pretty high. on the order of 8 bar... 120psi not good for hose clamps!!! get those fittings off, and have a set of hoses built at napa or an aeroquip shop... with high pressure connections.

shesh! what you see there was on my 240D since 1990 and the PO's last engine rebuilt 15k miles ago,

I'll either get used proper 240D lines or new hydraulic ones.

layback40 · #13 03-28-2010, 12:25 AM

Hydraulic are cheaper.
There are threads on here about them.

2.5-10 · #14 03-28-2010, 12:26 AM

Quote:

Originally Posted by layback40

you need to wire the small connector on the alt to the idiot light (ig light) the main connector just goes to +12v like you said.

Those black hoses need to be piped to the cooler.

I couldnt see the power steering hoses any place.

You need a good strong relay for the glow, it is best set up through a push button that you hold in until it starts. You dont leave the GP's on once it starts.

You need a vac switch to turn off the motor. it is normally part of the ignition switch. It needs to turn off the vac to the IP stop when the ignition is turned on and turn the vac on when the ignition is turned off. You may be able to find a suitable elec/vac switch controller off the pollution control of something. it needs to be normally open, power to close & vent the outlet. The alternate would be to rig up a kill knob with a cable, attached to the shut off leaver on the IP.

forgive my ignorance, which idiot light?

the P/S hoses are the nearly the same size as the 2.3 hoses and the fittings look spot-on. not that I even need Power Steering in this thing, still. may as well install it.

I am familiar (vaguely as it may be) with glow relays from my 2.5 Turbo but a dash button would be just as good for someone like me who doesnt mind hassle when driving an old diesel.

can that be a small cable wired to a small arm on the IP? if so, I know which thing you are referring to. if not, I'll have to look for a vacuum connector on the IP

since I am unfamiliar with all that fancy electric vacuum stuff, I'll just have to cable up a kill knob

thanks again for the help guys!

2.5-10 · #15 03-28-2010, 12:27 AM

Quote:

Originally Posted by layback40

Hydraulic are cheaper.
There are threads on here about them.

well then, I will have to find myself a decent oil cooler and get some fitted lines made.

why is the oil pressure so much higher on these motors than some other motors which top out at 4-6 bar?