I own a '77 240D that currently does not run (and no, I'm not selling it and buying a 300TD cause this car is special ). I want to pull the 4 cyl. out and put the 5 cyl turbo Diesel in it. I plan on getting a donor car to pull the motor, radiator, rear end, etc out of and put into my 240D.
What else is the difference between the 240D and the 300TD besides the engine and drive train? I'm asking because I would put the 300TD badge on it when I do the swap, but I don't want to miss minor details

engine mounts and shocks, flex tube to exhaust pipe,
tachometer, a/c compressor location, no gorilla knob,
key switch and vacuum setup. drive shaft will be
shorter, differential the same.
after 1980; no idle knob, different glowplugs and relay.

possibly diferent springs

don

No gorilla knob on a '77 240D

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Never a dull moment at Berry Hill Farm.

You'll need the entire exhaust line, the turbo is a larger ID.
I believe you should swap the tranny from the donor car too.
I'd leave the 240D and not put any turbodiesel badge on it so it will be real stealthy that way!
DDH

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'95 E320 Wagon my favorite road car. '99 E300D wolf in sheeps body, '87 300D Sportline suspension, '79 300TD w/ 617.952 engine at 367,750 and counting!

The air intake snorkel and scoop are bigger on the turbo.and the fun one... the heater control valve and coolant lines....... The turbo uses the small monovalve deal in conjunction with the auto climate control. If your 240 has the "coffee can" heater contol valve with "15" vacuum lines running to it mounted on the pass inner fender, well that's gotta go...

Iam doing a similar swap, a 300D non-turbo into a 300TD.
Lesson #1 and Iam glad I figured it out first was to buy the whole donor car not just the engine, because you will have a puzzle on your hands and you will need some parts from the 240 and some from the 300TD...
Lesson #2 is to have a complete car as reference so that you can look at how things should go together, if that's not practical then take lots of pictures before you take stuff apart.

Once you have your donor engine and trans out now is the time to clean and inspect everything, you will save time and grief in the long run.

The Haynes manual says that one can take the engine out and leave the tranny in. Don't listen to them, it will take twice as long to pull the engine that way....

Throttle shaft may be different.
What about front springs?

The climate control system is independent of the engine. My '79 wagon had the servo type system, it works beautifully with the turbo transplant. I would never believe anyone could convert the servo to a mono valve system.
Leave the CC system as-is, install the turbo engine and hook the water pump to the system in place. If anything might be changed with respect to the CC, it could be that the earlier version water pump housing would interface better than the one on the turbo engine, but I'm not positive mine was changed in that respect.
DDH

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'95 E320 Wagon my favorite road car. '99 E300D wolf in sheeps body, '87 300D Sportline suspension, '79 300TD w/ 617.952 engine at 367,750 and counting!

The taillights on the 300D had a little chrome strip underneath it whereas the 240D doesn't

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Jason

00 Subaru Legacy (fun wagon)
96 Nissan Sentra (disavowed)
82 300SD (garage queen, will run again hopefully)
87 300DT (Gone: 10/15/2010)