PeachParts Mercedes-Benz Forum - Repowering 240d with non turbo 5 cyl

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Repowering 240d with non turbo 5 cyl

I know this has been discussed before..But a virus struck and I have lost all my notes.
I have a 240d with a oil guzzler motor -#3 hole is oval! I have a verrrry rusty 300d with a factory exchange motor with 2k miles as a donor vehicle

Will the 4 speed bolt to the 5cyl? Has any one did this ? If not and I use the slushbox I know I have to shorten the drive shaft 1 inch. What about the linkage?
Thanks in advance!

It will work and it has been done with the 617 turbo. R Leo has a nice thread on the job

Where can I access this post with the swap thread? This forum is great !

some other guy in California was doing this also. Forget his name. He is no longer posting but the archive search will give ya the infos.
Be patient.

It can be done...

It looks like the flywheel balancing from the 240 and shortening of the drive shaft will be the biggest issues. Of course the engine/ auto trans and diff from the 300d would be a direct bolt in. The 4 speed would give it more zip but it would be more money and hassle to do it . I wonder if the driveability difference would make it worthwhile?

Your call. If you like manual transmission then I would say it's well worth it.

If you are ambivalent, then go the easy route and swap in the other drivetrain. The drivetrain swap will be less involved but either way it's not 'plug and play'.

It might seem like a small almost insignificant "problem" but I think the throttle linkages would also need some modification if you didn't do the straight swap... don't forget the little things that will make it a pleasure to drive and start (and stop)!

I swapped a non turbo five cylinder into my eighty three two forty. Love it. I also swapped in a 307 diff from a 300 turbo and my five speed manual tranny. My 300d is a euro. I get 35 mpg hiway and over 20 town with it. Great driveabity too. The 300 has a lot more torque than the 240 even with the 307 diff.

You want to also go to a 346 rear end as a minimum to drop the rpm on the highway. That is what the 300 na came with.

You will also want a speedo that matches your rear end to make it all compatible.

And a 300 radiator.

It is a fair amount of work but nothing too complicated.

Oh and there is a motor mount on the back of the 240 oil pan that is not used with a 300 that must be removed and you will want to have a motor shock fabricated for the second motor shock used in the 300 motor.

Doing the whole swap would be the way I would go. The manual tranny behind the 617 is like driving the 240D on steroids. :D If you have both cars side by side all the little problems like linkage can be sorted out, and you'd have a fun car to drive.

I swapped in a 4-spd into my 85 300D, so I will say for the most part it is plug and play.

The 4-spd will bolt to the 5 cyl engine, use the FW from the 240 and have it matched to the auto FW plate. be sure to mark the plate and the crank so you then can bolt the manual FW to the same orientation. there should be a mark on the crank/FW.

use the 240D auto X mount for the trans mount. it has 4 bolts to mount it to the body.
The manual shifter will bolt into the same holes as the auto shifter.
The shift rods will have to be shortened and tweeked some to line up. not a big deal.
Use the front section of the 240 drive Line, and have it shortened and balanced along with the rear section at a good DL shop that can do the MB`s. good time to replace the U-joint and center bearing.
since you have both cars, then you will have all the parts except for the X mount. the 240 manual X mount is longer and only uses 2 holes and some have modifyied it. best to find a 240 auto mount.
The peddle assy will bolt right in, uses the same holes and 13mm nuts. the only difference between the two peddle assy, is, the manual with the clutch peddle has a longer shaft for the second peddle arm to hang on.

Your 240 will have the 3:69 diff, use the Diff from the 300D and it`s spedo. the spedo`s are matched to the Differential.

would be a good time to bolt on a new Master Cylinder while you have the peddle assy in your hands, instead of standing on your head working under the dash trying to bolt it on.

I picked up 3 mpg with the swap, and am pleased with it. I have the 2:88 Diff, and getting 30 to 31 plus on the Hwy. a 3:07 might be a better combination. it seem like with mine, there could be a gear between 2 & 3 and between 3 & 4.

Would I do it again? YES!!!

If some one has not done the swap and not interested in doing it, then you will hear all the reasons not to do it.

Will there be some expences to the job? yes. as with everything in life and worth doing, there is a cost.

have fun and take pictures.

Charlie

i just completed a 240d manual to 300d manual. well, a local shop did it for me. i was lucky enough to find a euro 300d with manual transmission attached. WOW what a difference. it really feels like a modern car. 1st gear is a little short -need to change the differential soon. my biggest complaint is the weight of the engine. i'm going to have to put bigger springs on the front. i just can't decide weather to get new ones or junkyard ones.

Did the swap 6 years ago and love it.

Quote:

Originally Posted by Army (Post 2780272)

nope not an issue. The throttle linkages on the 617a are different on the engine but the throttle input from the pedal is the same with I think the only exception being the rod that comes off the firewall to the engine. Or they might be the same.