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  #1  
Old 12-19-2009, 07:29 PM
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Location: Tampa, Florida
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240D Turbo Odyssey

After being inspired by Graminal (240dt) I decided to go down the 240D Turbo route myself. Its been slow going due to limited time and learning along the way, but slowly I've been gather parts and getting closer . . .

Some observations:

1. If you already have a pre-fabbed 240D turbo exhaust manifold, this is a pretty straightforward project. If you don't, it isn't.
2. I do not have access to welding on my own - so I am paying for those machine / welding services. If I had a place to do it, it would have been cheaper to buy my own welder and learn to weld. When I took a 300TD exhaust manifold to be modified for a 240D I realized just how far of a stretch this was - in fact, I think it would be largely impossible (see #3). If anyone has been successful in doing this, please tell me how.
3. Because of #2, I started looking for other alternatives. It seems that the 1968-1973 220 exhaust manifold (unmodified picture attached - at least that is what I think it is - I'm not sure if it is a Diesel manifold, or gas - I believe ones very similar to what I have, without the strange flat top outlet, exist, but I only found that out after I had bought mine) might be a possibility when modified. Modifications include an adapter from the exhaust outlet to the Turbo (as small as possible for shock tower clearance), and massaging the mounting holes to work with the 240D cylinder head exhaust manifold mounting holes as well as coming up with a cover for that strange top outlet (if anyone knows what this is, or does, I would be curious). Still, its going to be very tight against the shock tower, if fits at all. This remains to be seen.

If I ever get this done I will post a parts list as well as modifications (and pictures) that I made to the exhaust manifold in case anyone ever goes down this road again.

If anyone has come up with a better turbo exhaust manifold solution to this issue, let me know. At this point, doing this has become a quest. I've got a modified oil pan, a modified oil filter assembly outlet, and a GT2252 turbo with 3" exhaust ready to go. I never thought the space in a 240D engine bay would be an issue - but here I am.

Thanks to everyone on this Forum - I've only gotten as far as I have because of you guys.

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240D Turbo Odyssey-img_2987.jpg  
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  #2  
Old 12-19-2009, 08:49 PM
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Join Date: Nov 2006
Location: New Hampshire
Posts: 282
I hope it all goes smoothly for you.

In regard to the manifold, this is the reply I got from Bio240D 2 years ago when I was first thinking about my project.

"I used an exhaust manifold off of a 617 with an adapter plate that blocks off the port for the Fifth cylinder. This is quite easily accomplished. I'm a machinist, so I used a milling machine to make the port openings, but It could be easily done with a die grinder and some patience."

I'm not totally sure what he did but I don;t see why you can't just make some thing that fits into the empty port and then braze it into place. You would want it to bolt the many to something flat so it does not warp. Just an idea though.

There is a photo on this page of Bio240D's engine and some info about thecallaway kit.

http://www.superturbodiesel.com/std/callaway-240d-turbo-article-with-pics-t-456.html

On this page you can see the Rajay turbo kit photos and the angle piece that was used to convert the old style 240D (w115) exhaust manifold to turbo manifold.

Good luck.
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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
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  #3  
Old 12-19-2009, 09:27 PM
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Join Date: Jun 2007
Location: Bahama/Eno Twp, NC
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Hi, that manifold you show is off a gasser. The intake plenum bolts to the top of the that cavity with the flapper valve in it to give heat to the intake charge when the engine is cold.

The one on my UNIMOG is identical except for it being a 6 cyl.

Best of luck on your project!
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  #4  
Old 12-20-2009, 12:07 PM
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Thanks guys, great information - if I can get this (the 220 Gas) to work, at least I'll know where the raw material came from (220 Gas). The adapter that the machinist built is pretty slick - but I think due to space we're going to have to do another one.

I sent a PM to Bio240D to see if I can get some more information about his modifications. When I took my 300TD manifold to the machine shop and told them what I wanted to do they seemed very skeptical of the longevity of such a solution - and after looking at it with them I was reluctant because of only having 5 of the 6 mounting points secure - I can't tell from the picture what Bio240D has done to secure that 6th hole (where the 5th cylinder would be). Maybe he'll have some answers for me.

Does anyone have a picture of the "old style" 240D exhaust manifold (out of the car)? What years did that come on? I'll have to check my manuals at home. Something tells me when I see that it is going to be a better choice then what I'm doing with the 220 Gas manifold . . . ugh.

They odyssey continues.
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  #5  
Old 12-21-2009, 11:14 PM
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Join Date: Nov 2006
Location: New Hampshire
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Sorry I forgot to add the second link.

http://www.superturbodiesel.com/std/old-rajay-turbo-kit-240d-t-447.html

There are some good photos that should help you on your odyssey.

__________________
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
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