Gas to Diesel Swap - PeachParts Mercedes-Benz Forum

Baby-Benz · #1 03-01-2012, 11:10 PM

Hello, my name is Amanda.
My bf and I have a 1992 190E 2.3 (W201 M02 engine) and we have been wanting to do a diesel swap for a long time.
We have finally found a descent donor car. Its a 1985 190D 2.2L OM601 engine.
The car is junk except for the engine, no leak, turns over with ease and only has around 205,000km.
My bf has a strong background in automotive and we will be doing all the work ourselves at a friends shop (with help form friend).

If anyone has done a swap like this before, we have a couple questions:

-What gasser parts can be used for the diesel? (We were told that the our gasser transmission would be a near perfect fit.).

-What definitely needs to be swapped out? (i.e. Differential, fuel lines & tank, etc.).

-What may need to be replaced in the diesel engine?

-What should we watch out for?

-Any other information, tips or tricks???

Please, anything you can contribute would be very appreciated.
Thank you very much for your time.
Sincerely,
-Amanda

mach4 · #2 03-01-2012, 11:53 PM

I can't speak to any specifics on your particular swap, but I can offer you a fairly detailed thread on my project to swap an OM617 into a 380SL, which you can view here 380SL Diesel Conversion Project Yours might be close to a bolt-up affair or you may have big challenges - I just don't know.

I've attempted to show in my thread, the process, the problems and the solutions from start to finish. It may give you some insight into the kinds of things you might run into and a way to think about the project step by step.

As I view these kinds of projects there are fitment issues which involve clearances, mounting strategy and fabrication. Then there are hook up issues related to each of the systems - cooling, fuel, exhaust, driveline, electrical, oil, vacuum, gauges, intake, linkages, emissions and A/C. Each one will present a different set of challenges.

One piece of advice is to keep the donor car and the project car close. You never know what you'll need. Label everything and take lots of pictures.

And this forum is a wealth of information, experience and helpful experts.

Good luck!

aaa · #3 03-02-2012, 05:49 AM

Is the donor car automatic?

t walgamuth · #4 03-02-2012, 06:34 AM

You'll need to swap at minimum the engine transmission and rear end. the gas transmitssion might work but it will be set up for shift points that are higher than the diesel engine and you probaby would not be happy with the performance. I don't know if the fuel tanks are different or not but you will need to check that and swap the diesel tank in if it is. I would also look hard at the radiator and oil cooler as they might be different too. There are some differences in the instrument pod so it might be good to swap that too along with the wiring sub harness.

The exhaust is probably different too so you will want to swap that over.

Remember to keep the serial number of the donor car handy so you can use it when ordering parts.

The above advice about keeping the donor car close by is very good too.

Good luck!

Baby-Benz · #5 03-02-2012, 09:07 AM

Yes both are auto trans.
The diesel swap will take place in one shop two hoists side by side.
thanks
Sincerely
-Amanda

charmalu · #6 03-02-2012, 10:31 AM

As Tom mentioned, keep the serial number of the doner car. I usually knock off the VIN Plate that is attached to the door post on the drivers side. It has the vehicle identification # and date of manufacture etc... good if you have to order parts from the dealer or Classic Center.

Charlie

Murkybenz · #7 03-02-2012, 02:43 PM

A few links to a thread concerning removing a petrol engine and replacing with a diesel in a Mercedes r129 convertible.
Note the mention of machining the flywheel to enable the petrol torque converter to be used and therefore keep the petrol running gear.

pictures No:petrol out-diesel in - Mercedes-Benz Owners' Forums

http://forums.mercedesclub.org.uk/showthread.php?t=54012&highlight=brianbrian

pawoSD · #8 03-02-2012, 05:25 PM

I am doing the same thing in a couple months. I am keeping the gasser automatic trans as it was just rebuilt a couple years ago and shifts awesome. A 2.3 driven normally shifts well below 2800rpm in normal driving, so I see no issues with the shift points. Thats all bowden cable/vacuum adjustable anyways for the most part.

Serial number schmerial number. Mine is a diesel gasser!

No emission testing here.

Technically swapping vin's is much more illegal than swapping an engine....

Renntag · #9 03-02-2012, 05:41 PM

Quote:

Originally Posted by pawoSD

Serial number schmerial number. Mine is a diesel gasser!

No emission testing here.

Technically swapping vin's is much more illegal than swapping an engine....

The suggestion of keeping the vin handy (ie written down some where) is for ease of parts sourcing.

My question to the OP is simple: Why not just purchase a 190D? Seems like a lot of work to create something that is already available. I can see swapping a diesel into a model car that never had one as an option, like an SL. I have thought about repowering a 320TE W210 with the sedan's OM606 to have a diesel W210 wagon. I am unaware of a W210 Diesel wagon ever being built.

pawoSD · #10 03-02-2012, 05:44 PM

Its pretty easy to turn a 190e 2.3 into a 190d 2.2......thats what I am doing. Gasser engine is toast, car is nice, found an engine cheap.

ChinaClipper · #11 03-02-2012, 07:30 PM

The Glow Plug wiring must be installed, the instrument cluster on the gasser has the economy gauge, the transmission torgue converter may have a lower stall speed as do most diesels vs. gas. I would suggest doing the engine/tranny from the 190D. There will be some vacuum differences since the diesel uses a pump. the rear diff ratios may be off, check the manual and save the Speedo from the 190D. The Climate Control Unit will need sorted out as well. A major change in 1987...will be a nice car when done....

charmalu · #12 03-02-2012, 10:50 PM

Quote:

Originally Posted by pawoSD

I am doing the same thing in a couple months. I am keeping the gasser automatic trans as it was just rebuilt a couple years ago and shifts awesome. A 2.3 driven normally shifts well below 2800rpm in normal driving, so I see no issues with the shift points. Thats all bowden cable/vacuum adjustable anyways for the most part.

Serial number schmerial number. Mine is a diesel gasser!

No emission testing here.

Technically swapping vin's is much more illegal than swapping an engine....

Now reread what I typed up above.

"I usually knock off the VIN Plate that is attached to the door post on the drivers side. It has the vehicle identification # and date of manufacture etc... good if you have to order parts from the dealer or Classic Center."

Nothing about swapping VIN numbers. Just classic reading comprehension 101.

Charlie

PaulC · #13 03-02-2012, 11:00 PM

Is there a significant difference in engine weights? You may need to put the diesel front springs if so.

ROLLGUY · #14 03-02-2012, 11:41 PM

IMO you would be better off keeping the 190D intact and use the E for a parts donor. It would be a LOT of work to change over the drivetrain. I believe the entire engine/ interior wire harness will need to be changed, as many things are different electronically (emission controls and other electronic devices). That all would require the removal/replacement of the dash. As far as the climate control, there should be no difference from the D to the E. You would then have a source of interior parts as well. Also, if you are used to the power of the E with the automatic, you may not like the LACK of power the D has with an auto. My former 190D had the 5 speed, and it was barely almost not dangerous. The gasser is pretty peppy with a auto or manual, but the D with an auto would be dangerously underpowered. It is too bad one of the cars did not have a 5 speed, as that would have been the best way to go.

aaa · #15 03-03-2012, 12:01 AM

The electronic part is pretty simple, due to their being almost none to bring over from the diesel. The gasser electronics can stay in place, unused.