Permanent magnet, gear reduction starter mod for 240D
 

Since I am logged in, I thought I would post some pics of the starter mod I just did for my 240D.

I took a starter from a 91 560sel and machined the nose cone to position the pinion gear so it has full engagement.

So far I am very pleased with the mod. I put the engine in a different car and would not have been able to remove the original starter from the bottom and the turbo and intercooler blocked the top, so I needed a smaller starter from a serviceability standpoint.

If your starter is so poorly made to the point you need to remove it frequently, I suggest you buy better quality parts.

Turbo on a 616? Say more.

56mm is far too large for his engine. It surges on my 3.0L up to 2000rpm, it will do it far higher on his. What he needs is a GT1849V, or at most a GT2052V.
Not to mention the GTA2056V from the Liberty is notoriously unreliable.

It helps to read the entire post,

And I quote from my original post,

" I put the engine in a different car and would not have been able to remove the original starter from the bottom and the turbo and intercooler blocked the top, so I needed a smaller starter from a serviceability standpoint."

The original starter was still working, needed new bushings after 15 years of starts, but still got it started none the less.

I"ll keep that in mind, lol :P

There are several threads regarding putting a turbo on a 616. Unfortunately a quality discussion needs to take place privately given the current population.

Take a peek over on the performance tuning section and there is an thread about eeking out performance of a 240D that has some links to other threads from members who have been running a turbo 616 for several years. Unfortunately you will have to wade through the BS to get some insight, so put on your hip boots!

Edit:

I see that the problem has been solved.

Here is a link to my other thread, http://www.peachparts.com/shopforum/diesel-discussion/298277-om616-190e-chassis.html

I have to make the exhaust tube from the turbo, and the remote VNT control yet. When done, I can put the intake on and will take more pics.

I am really pleased with the starter. I am going to be very happy with this litle car. I also have a 6 speed manual that I will mod for this car as well, but first I want to get the thing on the road and rework the IP.

Other than the physical size of the 91 560sel Starter is there any difference in rotational speed (faster) or less Current Draw (my stock 84 300D starter draws 150 amps when cranking) that would be an advantage to some one trying to start in a Cold weather conditions?

I would imagine the 560 gasser starter has less torque than the diesel starter, which is what is critical when turning over a 20:1+ compression engine, which is over double that of a 560....the 560 may be bigger, but its easier to rotate. MB sized/designed the starters as they did for a reason.....

^^ He has a special application for it and understandable why he chose this route instead of the stock starter.

It would be interesting to see how well it works and it's longevity factor.

Keep us informed.



.

150 amps with a conventional starter is not bad. I doubt that a permanent mag starter will draw any less spinning a 5 cyl diesel because the motor is small. It would be interesting to check the draw though to know for sure.

It spins the 616 like nothing. Cranking speed is faster than the one I took off, but the bushings were shot, (the armature was probably dragging, lol), but it spins it at a good speed, and it seems quieter too.

I looked at the specks that I could find for starter output on a diesel and gas starter and found one speck that said the 60X starters were 2.2 Kw and the gas was 1.7Kw

The starter came with a sheet that had test results on it and it maxed out at 1.9 Kw but it was tugged down pretty good and was drawing over 300 amps. Just from the sound of the one I have I am not at all concerned it will do the job well.

Time will tell how well it will do in it's new home.