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  #1  
Old 09-27-2003, 05:15 PM
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240 Engine Swap Time Estimate

I'm going to be doing a 240D engine swap. One good body with bad motor, one bad body with good motor.

What is a reasonable time estimate for doing this (engine only)
or Engine and Transmission (from auto to manual conversion)

I am a pretty well versed mechanic, so it shouldnt take me forever, right?

Thanks for any info you can provide.
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2004 Saab 9-5 AERO 138k (for sale)
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1999 Toyota Tacoma 4x4 - 132k (sold)
1999 Saab 9-3se -- 84k (sold)
1986 MB 190e 2.3 16v -- 221K (sold)
1985 MB 190e 2.3 16v euro -- 145k (junked)
1992 Saab 9000t 5sp. -- 142k (sold)
1994 Subaru Legacy -- 264K (sold)
1998 Audi A4 1.8TQ -- 102k (sold)
1983 MB 240D stick -- 160k (sold)
1988 Saab 900SPG -- 156K (sold)
1983 MB 300D -- 270K project or parts (sold)
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  #2  
Old 09-27-2003, 05:27 PM
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If you work fast one day should not be unreasonable. The 240D is probably just as easy to pull the engine/tranny as it is just the engine. If you work medium pace I would plan on taking a Saturday and Sunday.
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  #3  
Old 09-27-2003, 08:48 PM
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Here are the times from Nichol's-Chilton Labor Guide:

R&R Engine-does not include component transfer 240D.....10.8 hr

Don't forget you have to do 1 and half of these. One LONG day, but better as a weekend project.
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  #4  
Old 09-27-2003, 11:19 PM
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I crammed a similar project into 6 weeks

However, it was my first time and I added several other components.

I might add that a job that "has to be done" is far less rewarding than one that "gets to be done". I'd plan it when you aren't pushed for time so that it is more enjoyable.

Don
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Last edited by diesel don; 09-27-2003 at 11:27 PM.
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  #5  
Old 09-28-2003, 01:31 AM
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I did a switch last week and one thing I learned that helped was to keep the cross member attached to the tranny. When the engine rests on the mounts then jack up the tranny and bolt up the cross member. (this was with a manual) getting the clips back on the tranny linkage can give one the"fits" too Good Luck, its really not a bad job.
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1979 240D 5 spd, 40K on engine rebuild
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  #6  
Old 09-28-2003, 12:46 PM
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Thanks for all the input.

I think I will do it in two days. I'm actually doing this for an aquiantance, so its about the money for me.

I'm thinking of charging $1000 even, for parts and labor. I can get the parts car for $200. Does this sound like a reasonable price to you guys?

Thanks again for the advice.
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2004 Saab 9-5 AERO 138k (for sale)
2000 VW Jetta GLS TDI 215k (sold)
1999 Toyota Tacoma 4x4 - 132k (sold)
1999 Saab 9-3se -- 84k (sold)
1986 MB 190e 2.3 16v -- 221K (sold)
1985 MB 190e 2.3 16v euro -- 145k (junked)
1992 Saab 9000t 5sp. -- 142k (sold)
1994 Subaru Legacy -- 264K (sold)
1998 Audi A4 1.8TQ -- 102k (sold)
1983 MB 240D stick -- 160k (sold)
1988 Saab 900SPG -- 156K (sold)
1983 MB 300D -- 270K project or parts (sold)
1986 MB 280SE Euro stick -- 150K (sold)
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  #7  
Old 09-28-2003, 03:49 PM
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I have done the switch twice (616) and two days sounds OK to me. Last time I used an impact wrench where I could, like the flex coupling, that helped alot (jack up ONE side of the car so you can turn it). Have one of those spreader bars that you can tip the engine & tranny with. One problem I had both times is that the oil pressure gauge line would not turn at the filter housing. The plastic line was froze to the brass fitting so I just chopped it. a $50.00 mistake. Next time I took the instrement panel out and had my wife turn the line...dah:p
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1985 Euro 300TD 5 spd 220K
1985 Euro 240D 5 spd 130K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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