I need some help fast! Two friends of mine each have 240D's. One friend's 82 model toasted a rod and crankshaft. I would like to rebuild it but am unsure of where to get a crankshaft without paying $700 for a new one!!

But the real issue is this: the second friend's 78 240D is old and rusted out and just sits around, but it runs pretty good. He offered it for the other fellow to install into his 82 model. We have both motors out and have already swapped most of the accessories until we got to the air conditioning system. The 82 uses the GM Rotary and the 78 used the old York compressor. Located on opposite sides of the engine... but the real kicker is that the 82 has holes cast in the block for the compressor on the lower left side; the 78 does not have them so it means we need to either a.) convert the 82 to the York compressor (which means rewiring a bit, or b.) getting a different later model motor. Also, the glow plugs are the old big, loop type.... which needs to be looked at as well...

So recap of questions:
1. any ideas on where to get a crankshaft for cheap?
2. any ideas on the old type engine going where the newer engine came out for the a/c compressor mounting?
3. how would I rewire a rotary style wiring for the York type?
4. how would I put the wiring harness for new style glow plugs onto a head with the old style glow plugs?

Thanks,
JMH

Been there, done that.

I put an early engine into a late chassis. Here's what all is involved:

First off, don't use the York compressor, simply unbolt the late compressor from the late engine before removing the engine, and then swing it out of the way and wire it up so that it will stay out of the way. This way you won't lose the charge or have to mess with it . You will have to work around the hose that comes across the top front of the engine, but it can be done.

Secondly, the transmission mounting pattern is slightly different. The transmission will bolt up, but will not accurately index. There is an adapter plate that bolts to the engine and bolts to the transmission. Simply remove the flywheel or flex plate from both engines, take the adapter plate from the late engine and bolt it to the early engine. Then the late transmission will properly bolt to and accurately mate with the early engine.

Last main issue is glow plug wiring. The late pin type wiring, relay and everything is TOTALLY different. You have two choices:

Buy a "quick glow" kit that consists of bushings that will adapt pin type glow plugs to the early engine allowing you to use existing wiring, relay, et al.

Second choice, mount the bar fuse holder on the firewall behind the engine. Wire one side of the fuse holder to the rear glow plug just as it was in the early chassis. Then wire the other side of the fuse to a heavy relay, with the other contact post of the relay wired to the hot side of the battery. This is an 80 AMP circuit so use something like 6 or 8 gauge wire. For the coil side of the relay, simply put a momentary switch in one of the switch holes in the top center of the dash. I used an electric window switch for this. It looks factory. Simply press the switch for a few seconds to manually glow, then light it off. You will quickly get the hang of how long to glow depending upon how cold it is.

I did this on my 240D a few years back to utilize an early engine temporarily and it all worked out great.

Good luck,