I have purchased a 1979 240d with a manual transmission as a parts car. Also, I am trying to purchase a 1982 300td wagon, however it has an automatic transmission. It is possible to take the engine and manual transmission from the 240d and swap it out for the 300td. The 300td has a 5 cylinder engine and the 240 has a 4 cylinder. The parts car has all the parts for the transmission and it is basically a full car. It this possible without doing any modifications. Does it just bolt in? Any information would be appreciated. Thank you!

Well, yes it is possible to make this swap. But why do you want to install a 67 HP engine for a 123 HP engine?

Is there something wrong with the TD engine? If not, the 240D manual transmission will bolt up to the OM617 engine. If you go this route, all you need is to bolt in the peddle assembly, remove the auto shifter for the manual shifter. uses same mounting holes. you will need a trasnmission cross mount from a 240D automatic. It is wider and uses 4 mounting holes instead of the 2 the 240 manual uses. You will need to use the 240 front piece of DL, and have it shortened and balanced.

This mod have been done many times by many forum members.

Just noticed this is hyour first post. Welcome to the forum.



Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Well first of all, the 5 cylinder turbo diesel is a problematic engine, the turbos give out and engines aren't that reliable. Mercedes went wrong when they decided to add the fifth cylinder. The 4 cylinder in my opinion is one of the best most reliable engines out there. No turbo, no electronics, and way easier to work on.

Can you link me to more information about the swaps from the forum?

Thank you, i have recently gotten into vintage Mercedes. I though registering into a forum for my question will be a good idea. Anyways thank you for the response and i will probably be posting more questions.

Although I don't agree with your assessment of the five cylinders, since you have the parts car, you can go about whichever direction you choose.

If you decide to put the manual behind the five cylinder, you would end up doing a little fabrication for possibly a drive shaft, shift linkage and a clutch hydraulic line.

If you put the whole engine and transmission in the wagon, you will probably have most everything you need. I would never do such a swap without the entire donor car close at hand which sounds like is not a problem for you.

Keep us posted.

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2001 SLK 320 six speed manual
2014 Porsche Cayenne six speed manual

Annoy a Liberal, Read the Constitution

I think i am going to switch the whole engine and transmission since i have all the parts

Wondering if you would want to expand on "not that reliable". Many of us are in this hobby because of the reliability of the om617, and IMHO the turbos rarely fail except under abuse. The 4 cylinder diesel is not very different in design from the 5cyl.

__________________
TC
Current stable:
- 2004 Mazda RALLYWANKEL
- 2007 Saturn sky redline
- 2004 Explorer...under surgery.

Past: 135i, GTI, 300E, 300SD, 300SD, Stealth

If the only reason for doing this swap is your perception of the reliability of the OM617 over the OM616, better do some more reading before you do something you may regret. There is really practically no difference in the general (theoretical) reliability of these engines. There were no major design issues with either engine ( unless you want to talk about the air cleaner bracket on the OM617, which was a PITA, though really a nit). That TD is going to be dog slow with that engine. A better swap MIGHT be the 4 speed transmission.

You are also going to lose the rear hydraulic suspension swapping engines as the OM616 will not have the pump. What are you going to do about that?

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80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)

Well since you already have the 240D engine trans combination, it will just drop right in the TD body. both bodies are a W123 chassis. driveline should also work from the 240 w/o any modifying.

I didn`t know the turbo engine was a bad decision for MB. they made a bunch of them, and have proven them selves very well. I have 2, one in a 300D and one in a 300SD. also a 240D 4 banger.

There is also the 617NA, which is a 240 engine with one more cylinder. then you go to 88 HP from 67 HP. the Turbo engine is a beefier engine than the 617NA.

which ever way you want to go, you will get help from the members. you will get opinions from many that it is not a good idea, why do you want to do it? what is wrong with the original combination?

The TD has a self leveling system that is run by a pump on the front of the head. the 240D OM616 engine does not have this. you will have to over come this little problem.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

hmmm...i think the wasp nest has been shaken

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Ben
1987 190d 2.5Turbo

I have just had better experience with the 4 cylinder engine. I have had many friends that have owned the 5 cylinder and they are not happy with it. Why need another cylinder if the 4 cylinders is plenty. Also, I talked to a mechanic and he said that any 5 cylinder diesel engine is a problem to work on it and adjsut it.

I think you should reassess whatever or whomever you are using for information on this topic.

I have been active on various Mercedes lists since about 1995 and have never, ever heard that assessment of OM616 superiority vs. OM617 before.

I suspect what you have read or been told or experienced is based on a set of very subjective experiences. There is nothing wrong with adding a fifth cylinder, engineeering wise, if it's properly done. And when the OM617 was unveiled it was regarded as a fabulous piece of engineering.

Some people are passionate about 240Ds because of the elegance of simplicity. But they aren't markedly more or less reliable than the 300 series in a w123 chassis.

You mention electronics. OM617 Turbos don't have any electronics, except for 1985 models that have a rudimentary ECU for EGR control only.

Turning to your specific situation, someone else already mentioned the drawback of the SLS pump being driven off the 300TD's head.

The other issue is that, not only are you moving to a motor with much lower power output (best case), you are putting it into a wagon chassis, which is about 500+ pounds heavier than the sedan.

Also I think you will need to install the front springs from the 240d, or the front end will be sitting way too high without the weight of the five-cylinder for which it the springs were spec'd.

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

Eh, I guess, I was just asking for the reasoning behind it since many of our own experiences differ from his in that regard.

The swap itself isn't hard but getting that SLS pump on the OM616 might be a significant challenge. In the nonwagons its not an issue

__________________
TC
Current stable:
- 2004 Mazda RALLYWANKEL
- 2007 Saturn sky redline
- 2004 Explorer...under surgery.

Past: 135i, GTI, 300E, 300SD, 300SD, Stealth

Well all three engines, OM616, OM617NA, OM617 Turbo, all have to have the valves adjusted every 15K miles. they all have a timing chain that has to be checked for streatch periodically. they all use the same fuel and oil filters. and for the most part, use the same starter.

None of these engines are electronic, they are all manualy injected.

I suppose if the turbo is a problem, you could remove it and the manifolds, and swap in a set from a OM617NA. although the Turbos will last the life of the engine if properly taken care of.

Iam wondering about this mechanic you got advice from.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

" some people are passionate about the 240ds because of the elegance of simplicity" The simpler the better and more reliable.

I am not sure what kind of adjustments you might have been talking about specifically, but the 5 cylinder is going to have just about every adjustment need as the 4cylinder.

To each his own

__________________
TC
Current stable:
- 2004 Mazda RALLYWANKEL
- 2007 Saturn sky redline
- 2004 Explorer...under surgery.

Past: 135i, GTI, 300E, 300SD, 300SD, Stealth