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  #1  
Old 01-29-2003, 08:24 AM
LarryBible
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Swapping an Early 240D Engine into Late Chassis

For anyone who might be considering swapping an early (serial glow plug) engine into a later 123 240D(pin type glow plug engine) car, I have done this and here are the things you need to take care of:

To begin with, there is an adapter plate that bolts to the rear of the engine to mount the transmission. All the engines are the same, but the transmissions are different, so you will need the adapter plate that goes with the original transmission that remains in the car. If a manual transmission car, you will have to remove the flywheel to change this plate.

If the car is an automatic, use the transmission vacuum contraption from the top of the valve cover that goes with the transmission you use.

You need to use the starter that goes with the engine you are using. There is a subtle difference between early and late starters, so see that you use the right one. In this case you would use an EARLY starter, because you are swapping in an EARLY engine.

Next is the difference in a/c compressors. This is no problem. Even an early engine has the bolt holes to accept the bracket for the R4 compressor. You will just have to reclaim the bracketry from the engine that comes out of the car.

Lastly is the glow plug issue. Since my engine swap was for temporary reasons, I simply used a Ford starter relay to transfer high current from the battery to the glow plugs. I mounted a fuse holder that came from the early car. I then used a pushbutton switch on the dash to actuate the relay. It's pretty easy to get a feel for how long you need to glow depending upon weather.

The better alternative to the relay and pushbutton for a permanent swap, would be to get the fast glow kit that provides bushings to use pin type glow plugs. Then you simply use the glow plug wiring harness from the original engine.

It's been about three years since I did this, so it could be that I have forgotten something, but I think these are the main items that must be considered.

I hope some of you can find this information useful.

Have a great day,

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  #2  
Old 01-29-2003, 09:46 AM
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Join Date: Sep 2001
Location: central Texas
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That is very helpful...

I think you underestimate the value of your pushbutton arrangement for your glowplugs...I think that is a great system for all cars since it takes the key switch out of the circuit....
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Old 01-29-2003, 03:05 PM
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Everyone ought to read their LarryBible

Good stuff!
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  #4  
Old 01-29-2003, 03:30 PM
300SDog's Avatar
gimme a low-tech 240D
 
Join Date: Jan 2003
Location: central ky
Posts: 3,602
Thanks Larry.... an excellent article / one of many I've downloaded and printed - sticking the page in back of my repair manual.

Am guessing that transfer of newer engine into older 115 body follows identical procedure..... yet also adding newer glow plug relay to older wiring harness.
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Old 01-29-2003, 08:14 PM
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Location: Ca.
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Larry, I tried to help this guy do just this same thing and the throttle linkage was quite an obstical. Chris
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My Truck.. 2007 DODGE, 5.9 Cummins, 6spd stick, 4X4. My car..1977 240D, OTHER WHEELS...1955 VW Oval window bug, European Delivery (Holland) with a 1700cc, 2 barrel, Porsche drum brakes. 1939 WILLYS Pick-up. 1967 Triumph 200cc Tiger Cub. 1976 Honda 550F 4cyl Motor Cycle.
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Old 01-29-2003, 08:21 PM
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Location: central Texas
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Chris, take it from an old Hot Rodder... switch to a hydraulic accelerator anytime you do something like this... well worth the saved time...

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