Unless the 616 is a way different casting then the 617 is should be really easy to put piston squirters in. Alll of the engines I have looked at have the main galley down low making it easy to drill and tap for squirters.

http://www.rallyrace.net/jvab/spgm/index.php?spgmGal=Volvo_Rods__Pistons_Squirterizational_Mods

On the oil pump issue I bet you could find a higher volumn pump to handle the extra demand. On my tired 143000 mile motor, a turbo with no feed restrictor I'm still seeing close to two bar idle oil pressure with a really hot motor and newish oil. Mercedes says at idle down to 0.4bar is fine. (I don't have my book handy but its silly low).

I always thought that the sodium was just a way to get better heat transfer out of the valves not to keep them from expanding. If the heat from a higher output motor is going to make then expand with say EGT's in the 1000*F range, then how come gassers don't seem to have issues with valves expanding and wearing out the guides at way higher temps. I mean I can make the exhaust manifold glow orange in my Merkur turbo but not even close in the mercedes.

Just some of my thoughts

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1998 Mercedes E300TD

1983 Mercedes 240D Turbo, 131bar injectors, Cosworth intercooler and 63' Ford Falcon radiator, Ardic Parking heater, Headlight wipers, Best 38.6mpg.

1973 Saab 96 Rally Car, 1.8l V4 with all the race bits

There is no 'reasonable' means of approaching this. Hours of fabrication / casting.

Unless you are lucky enough that the first crankshaft retainer from a 5cyl will fit into the 240, then just tap the gallery for the tube that runs from the pump to the gallery?

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if the heat is not transferred quick enough, the valves expand. And they do so unevenly. This depends on material of the valve. Each metal has a different coefficient of expansion.

I am not sure about the gassers, but it may be that the valves are thinner (less material=less expansion) and the clearances are enough to compensate.

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Honestly, I've only ever had the oil pan off the 5cyl twice, and never looked at a 4cyl before, so I really don't know what this is all about. Sounds ugly though, I admit. I wonder if the Force Motors engine has better oiling?

Without crunching any numbers, I'd be willing to place bets on a force motors long-block, bosch pump with VW pump governor guts, and a HX-30 or HY-35 being a hell of a combination for Mercedes superturbo glory, and not costing anything near a Myna pump retrofit + engine rebuild. If the force motors isn't any different from a stock 616, then this whole thing could be done with junkyard components, and a bit of patience, for under $1K.

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99 E300 Turbodiesel 100k