Done! 240D is now 300D turbo 4 speed - PeachParts Mercedes-Benz Forum

junqueyardjim · #1 06-22-2011, 08:24 PM

It took me 14 months, but I only work in fair weather. If it is to hot or to cold, I don't do it. Then last summer I had surgery on both eyes also. And it was so dog gone hot! But I started the conversion in April 2010, after toting the car home from Bradenton, FL in the fall 0f 2009. It is nice, it runs out great. I started it up yesterday, got it finished today and put on about 30 miles. Runs excellent, my "no balance" swap worked out good. I had no starting point on the 240D because the engine blew, chain broke, cam towers broke, so I had no idea of the position of the crank flywheel on that one. Neither engine showed a balance point, so I just put it together, froze the pilot bearing hard to get it in the small hole of the 85 crank and I had an industrial school shop in Tennessee was very happy to let their trainees shorten the drive shaft 4 inches. I used the 240D flywheel and yes the engine does decelerate very fast, so you have to stay on top and use your best form when shifting. To double clutch is even better. The car hasn't been run since 98 and it seems the body mounts are a bit hard. Well, lots of time to look at that and the other things that still must be done, signal lights, radio, install new antenna, engine shut off is not working. I did not install any AC stuff. AC costs too much on these old cars and as long as we have one car with air for the Dear Wife, that is all I need. Fuel gauge is not reading and temp gauge is out also. I installed a boost gauge, about the most I saw was 7 pounds, but I didn't push it too hard - really never do that much any more. You get used to those nice Thomas School Buses and then you start driving the car the same way. Diesel is high, but I hope that I can pull about 30 MPG on this one. I put the differential from the 85 300D into this 83 240D. Speedometer is off by more then 12 percent. Man those little 240D's really must buzz at 75 MPH.

charmalu · #2 06-22-2011, 10:20 PM

Good to hear you got her up and running. that is the most awsome feeling when she finally comes to life after you have had parts all over the shop. She lives.

I have been getting between 29+ and 31+ out on the highway in our 85 300D 4-spd.

Swap in the 85 spedo also along with the 2:88 85 differential. then you will be right on.

having the 240 with a OM617.952 engine is the best of both worlds. simplicity of the 240 and the zoom of the turbo engine.

Charlie

leathermang · #3 06-22-2011, 11:41 PM

Quote:

Originally Posted by junqueyardjim

....Man those little 240D's really must buzz at 75 MPH.

1. Sound deadening.
2. Can't beat me the first 50 ft from a stop....
3. LOL

smiffy6four · #4 06-23-2011, 03:56 PM

I'm pondering the exact same swap; I have a 300 turbo motor from a wagon and a 4 speed manual box from a 300d. Are these engines externally balanced? I would be using the flywheel/clutch assembly from the non-turbo on the turbo engine.

My 240d is an 83 auto..........

junqueyardjim · #5 06-23-2011, 04:16 PM

Well some of the people here have gone to great lengths to balance the assembly. I think if you can't find a balance mark on the parts they are good to go. I don't know what the balance mark is as I have never seen one, but I am told it is a check mark imprint on the flywheel and on the end of crank. I put mine together, (worried a bit about the balance) but it all worked out OK. I have had it briefly to 70mph and it is fine. My flywheel is from the 240D and weighed considerably less then the 300D flywheel, so that is good for you. With the lighter flywheel the engine decelerates quite fast during shifting and it makes shifting a bit less smooth. I hope it doesn't take you 14 months to do the job. Remember it is hard to get the throw out bearing into the end of the crank on the 85 engine. They made that hole just a little small. However, I put the bearing in the freezer overnight, and then easily pounded it in with a big socket driving it all the way to the end. The crank was nice and warm sitting in the sun on 4th of July last year. That helped also, but up in Ontario where you never or rarely get a 4th of July day you could give it a nice bit of heat on the end of the crank with a propane torch.

leathermang · #6 06-23-2011, 04:19 PM

So you would be using a flywheel from a 5 cylinder on a 5 cylinder turbo model ?
I know the FSM says not to use the 240 flywheel on the 5 cylinder but many people have done it.
The balance question... or matching the new flywheel to the old one is addressed in the 617 FSM... but it is hard to understand just when it applies to what....I think that the engine was balanced internally when coming from the factory.... but there is no way to redo that.. so the best you can get to is to match to the current flywheel...
Which, on cars this old, may not be the original or positioned as it came from the factory...
Basically it is a messy situation and I hope you can bring some light to the situation...

smiffy6four · #7 06-23-2011, 04:24 PM

Thanks for the speedy replies

Was the engine basically a bolt in? Is there much difference in the power of the turbo vs non-turbo motors?

Wondering if it would be simpler to install the 300d motor and the 4 speed that came with it?

leathermang · #8 06-23-2011, 04:29 PM

OH YES....if you have the 5 cylinder with the 4 speed attached... you are way ahead ....

The difference is 50 percent more hp..with the Turbo....

but if you have the IP / 5 cylinder which came from the FACTORY with the manual shift..

you have the perfect situation in my opinion....with lots more room in the engine compartment to deal with stuff....

later,
Greg

smiffy6four · #9 06-23-2011, 04:35 PM

Quote:

Originally Posted by leathermang

OH YES....if you have the 5 cylinder with the 4 speed attached... you are way ahead ....

The difference is 50 percent more hp..with the Turbo....

but if you have the IP / 5 cylinder which came from the FACTORY with the manual shift..

you have the perfect situation in my opinion....with lots more room in the engine compartment to deal with stuff....

later,
Greg

I do indeed have the 300 motor and trany/driveshaft/pedal set/clutch master & slave.......I believe it is the factory setup

junqueyardjim · #10 06-23-2011, 04:36 PM

I would agree 100% on that. If I had a good strong non turbo with the four speed attached and it is still the factory setup except maybe a new clutch along the way, I would be inclined to use it rather then to dismantle and do a hook up where it is possible you could have a balance problem. The turbo is good, I love it, but the 5 cylinder NA is a fine way to go, especially if you don't have an altitude problem.

leathermang · #11 06-23-2011, 04:43 PM

Quote:

Originally Posted by smiffy6four

I do indeed have the 300 motor and trany/driveshaft/pedal set/clutch master & slave.......I believe it is the factory setup

OK... the two smartest people on the forum just agreed that is your best deal... Do not ask any other persons and do not read their posts if they offer opinions on this subject..
Just go put it together and enjoy it !!!

smiffy6four · #12 06-23-2011, 05:08 PM

Quote:

Originally Posted by leathermang

OK... the two smartest people on the forum just agreed that is your best deal... Do not ask any other persons and do not read their posts if they offer opinions on this subject..
Just go put it together and enjoy it !!!

Sounds like a plan!

smiffy6four · #13 06-23-2011, 05:52 PM

Quote:

Originally Posted by junqueyardjim

I would agree 100% on that. If I had a good strong non turbo with the four speed attached and it is still the factory setup except maybe a new clutch along the way, I would be inclined to use it rather then to dismantle and do a hook up where it is possible you could have a balance problem. The turbo is good, I love it, but the 5 cylinder NA is a fine way to go, especially if you don't have an altitude problem.

I've never had ana altitude problem(250ft above sea level here), but some say I have an attitude problem

leathermang · #14 06-23-2011, 06:18 PM

Quote:

Originally Posted by smiffy6four

I've never had ana altitude problem(250ft above sea level here), but some say I have an attitude problem

Since you have scored the buy of the century... $200 for your na 5 and manual trans .... we will not be putting up with much in the way of ' attitude '....

smiffy6four · #15 06-23-2011, 06:24 PM

Quote:

Originally Posted by leathermang

Since you have scored the buy of the century... $200 for your na 5 and manual trans .... we will not be putting up with much in the way of ' attitude '....

OK, I'll play nice