Plot thickens---240D engine/tranny swap to california emissions car. - PeachParts Mercedes-Benz Forum

silverfishk8 · #1 10-25-2003, 10:19 PM

OK, so I am in the middle of putting a regular 1980 240D engine and manual tranny into the body of a 1983 240d automatic california emissions.

my problem is this: i cannot figure out whether to swap the emissions stuff from out engine to new one. if i dont, than i have all these extra vaccum lines coming from god knows where.

also, i need the throttle linkage from the callifornia car, because the one from the normal engine is damaged. however, the throttle inkage is connected to intake manifold on california car. so i would have to swap that too.

so should i swap all the stuff and play it safe, so that i dont have any wierd vaccum promblems, or should i go to a junkyard and get a normal throttle linkage? would the linkage from a 1980 300D work? is it the same?

thanks for any input you can provide....

Rick Miley · #2 10-27-2003, 09:20 AM

Well, I can tell you that the stop lever on a 1980 240D is unique to that year and model. So if you get the linkage you need all of it. The part that connects to the intake manifold should be for the automatic transmission, which you won't have. That should make it easier. My vote would be to go with the earlier linkage. Much simpler that way. If you like, I can take some pictures of my linkage so you can see how it should go together.

silverfishk8 · #3 10-27-2003, 10:50 AM

Some pictures would be an enormous help. Also pictures of all the vaccum lines + connections under the hood would be extremely helpful (From firewall to brake booster to IP pump, to linkage....).

I am thoughly confused, to the point where I know that the engine runs, but I have no way to stop it from inside the car....grr.

Does anyone have a 1983 240D that they could take linkage and vaccum lines pictures for me? If I have the two sets of pictures together I bet I can come up with some working hybrid....

thanks again!

Rick Miley · #4 10-27-2003, 12:58 PM

I'd be happy to post pictures of the vacuum stuff, but odds are mine is not correct. The vacuum stuff on this car was a mess when I got it, but I have everything working now. Don't have a manual so I'm not sure if everything is connected the way it is "supposed" to be, but at least it all works.

silverfishk8 · #5 10-27-2003, 09:32 PM

Can't wait to see some pictures anyway. Thanks for the help.

Rick Miley · #6 10-30-2003, 07:31 AM

Linkage pic 1.

Rick Miley · #7 10-30-2003, 07:32 AM

Linkage pic 2.

Rick Miley · #8 10-30-2003, 07:33 AM

Vacuum pic.

Rick Miley · #9 10-30-2003, 07:35 AM

The originals of these, at 2272x1704 resolution so you can really zoom in, are here:

Linkage 1
Linkage 2
Vacuum

Rick Miley · #10 10-30-2003, 07:42 AM

Vacuum explanation, just in case you didn't know:

Brown w/ blue stripe goes to key switch for shutoff.

Green w/ yellow stripe goes to climate control.

Black w/ yellow stripe goes to cruise control actuator.

Yellow w/ gray stripe goes to vacuum reservoir in tunk.
Yellow goes to driver's door for locks.
Check valve provides vacuum from reservoir to door locks without leaking to other accessories when the engine is off.

silverfishk8 · #11 10-30-2003, 12:20 PM

Thank you so much. This should be very helpful when I try to get it all working this weekend. Ill be sure to post my results!

Rick Miley · #12 10-30-2003, 12:33 PM

Great. If anyone wants those hi-res original pics, please download them soon. I'll probably remove them next week to make space for other stuff. They're 1.5 to 2 MB each.