Greetings. I'm starting a new thread as I now understand (somewhat) what I have gotten myself into. I've spent a lot of time researching conflicting info, so I figured it would be nice to have a thread for this swap, well documented.

I have a 1970 220D with 4 speed manual trans. My motor has retired on me, and have determined that my best option is put in a 617.910 5 cylinder from another 114/115 chassis.

I have located one for $500 plus another $200 to get it to me.

Here's what I do know (correct if wrong):

1. The 617.910 was used in the 300d (114) chassis from 74-76, making it ideal for a swap into any 114/115. The oil filter is located correctly, the manifold will fit, and the throttle linkage will match up.

2. I will mark the position of the auto flywheel to the crank, and take it and my older 28 pound flywheel to a machine shop. They will put the two together and match my manual flywheel to the balance of the auto one from the donor. The engine was balanced with the flywheel attached and not always neutral. Some people skip this step, but it is an easy process. With the two together they spin them and look for a heavy side, and drill a little on the manual flywheel until it balances.

3. I will not need to relocate my transmission for the 114/115 chassis, shorthen my driveshaft, or linkages. On this chassis they kept the tranny in the same spot between 220D/240D/300D.

4. My engine mounts are the same. I will not need mounts.

5. The donor 617.910 uses a glow plug relay/timer system attached to key switch. My 220D uses a gorilla switch wired straight to the plugs. The 617.910 runs about 55amps, my 220D less. I need to check if the gorilla switch can handle those amps just to get me running. If not I will take the wire that runs directly to the glow plugs and use it as a switch wire for a starter relay I have lying around, wired directly to battery. Long term bosch makes a fast glow plug system with relay and timer, more ideal.


Things I am not sure of:

1. Radiator/fan/shroud setup. Will I need a different radiator for the bigger motor? I know a lot of stuff is overbuilt.

2. Rear end gear ratio. What I am running now, and what a 114/115 runs. And for freeway driving, do I want a rear end out of a newer 300td? Or will that even fit.

3. Accessories. Will my alternator bolt up. Are the vacuum pumps interchange, and should I keep my old one as a spare. Starters the same? Etc.


I'll keep this thread updated and document my progress, so when another person asks, and you can't sell them on getting a 123, you can just point them here.

Good luck with your adventure

__________________
General George - 1967 Land Rover 2a SWB 1983 OM617 Turbo

I don't think it is that easy.
You have to move the transmission back, shorten the drive shaft and shifter rods.
The radiator is different, in and outlets are larger on a 300D.
Alternator bracket is different.
The 300D uses engine shocks ,a dry air filter and a vacuum shut of for the engine.
You can use your vacuum pump and starter.

__________________

76 240 D. Bought in 1998 for $25.
85 300D. Got it for free with a bad engine. ( Sold )
60 Unimog 404. What was left of it, was given to me. Now powerd by 617A.
88 560 SEL. Bought without engine and trans. Now powerd by 617A.
67 250 SE. Cuope. For resto or sale.
64 220SE. For resto.

Hello,

Double check the engine mounts. The correct ones for the W115 300D are 115 241 08 13.

Marc-Andre

Thanks guys. Ive seen people say that on the 114/115 chassis the tranny doesnt move. But more are saying no. Regardless, I got a call today for a 220D right down the road. This project has gone wild as I wasnt planning on doing it so soon. I'm gonna look into this 220D motor and try to not get myself into trouble. But if anyone has done this 617.910 swap into a 114/115, I'm curious.

My original thread

New 220D owner, need direction