I have started a new engine build for my 240d. It was tired when I got it and now even more so. Will keep driving it until the new engine is ready, then swap.

I am starting with a rebuilt short block(1983 616) from another forum member, that opted to use a 617. This has new liners, pistons, rings, polished crank, and new bearings. I will rebuild the head using valves for the turbo 617 on the exhaust side. New cam, cam bearings, everything in the head basically. thanks to Phil from Peachparts for helping find everything.

Once this is together then I will mount the turbo, a k26 from a 300d while the engine is still on the stand. As I have found that reaming the pre chambers holes helped a lot on the old engine will do the same on the new one, and will for now move the tuned up ip over. A new pump will be built with larger elements and when ready will replace the old one.

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1977 240D turbo

Pics?

Here are some pics.

Have the manifolds altered and ready.For now I will stick with these, but if I get bored later may well make some new ones with a better design.

The cylinder head I have stripped bare, and new valve guides in and reamed.

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1977 240D turbo

Given that you have the head that far down, you could machine the PC tube bores in the head so you could put 617a (turbo) PCs in. If you had to, you could dremel the piston PC pockets a touch to make up for the size difference.

had not thought of that, is there enough thickness to the casting to allow it? It will be a few days before I get back to it, but will look at it closer. I do have an extra set of 617a pc's.

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1977 240D turbo

Found a little time to get the pcs out of the 617a, and machine the head of the 616 to accept them. They fit nicely, need to check piston clearance yet. Did ream out the burn holes a little also, .010

Valves are in. The exhaust valves from a 617a have a differant seat angle, so had to re cut the valve face to match the head.

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1977 240D turbo

Looks like a fun project! Are you doing anything with the oiling system? Adding cooling jets?

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-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

no piston oil jets. Will watch egt's. I have heard from others that the stock oil pump will maintain proper pressure so really not worried about changing that. It is a new oil pump.

Have it mostly together now, just waiting for a new cam.

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1977 240D turbo

I also remember reading about opening up an oil passage in either the head or the block to supply more oil to the cam spray rail. It is late now and I am tired, so I will look for the link to the article tomorrow.

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Well today is tomorrow. I can not find the article.

It mentioned that there is a passage, either in the block or the head, and it's cross section area is less than all the jet holes in the cam oiling tube that the passage supplies oil to. Opening it up to match the area of all the holes improved oiling to the cam and arms.

I'll look in the fsm and see if it shows where the oil passages are. I have the head on now, so not to thrilled at removeing it.

Still waiting for the cam, peachparts assures that it is on the way. So at least I don;t have to worry about getting it.

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1977 240D turbo

Here are the latest pictures. I want it to look factory, so at least most looking under the hood will think it is from the factory, so trying to use Mercedes pieces where practical. Plus why re invent the wheel. What already works good might as move over to this engine.

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1977 240D turbo

What are you going to degree the cam in at?

I am going to install mine a little advanced, or at least the "pre cam chain stretched" speck. This would help the bottom end, (pre boost).

From someone who also has a turbo on a Mercedes where it doesn't belong, Nicely Done! I was also aiming for a factory installed look with my install but I think you pulled it off better than I did. For my gas engine I also run the cam advanced, 3 degrees. Mercedes OE camshafts don't have a lot of overlap to start with but I believe it helps.

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90 300TE 4-M
Turbo 103, T3/T04E 50 trim
T04B cover .60 AR
Stage 3 turbine .63 AR
A2W I/C, 40 LB/HR
MS2E, 60-2 Direct Coil Control
3" Exh, AEM W/B O2
Underdrive Alt. and P/S Pulleys,
Vented Rear Discs, .034 Booster.
3.07 diffs 1st Gear Start

90 300CE 104.980
Milled & ported head, 10.3:1 compression
197° intake cam w/20° advancer
Tuned CIS ECU
4° ignition advance
PCS TCM2000, built 722.6
600W networked suction fan
Sportline sway bars
V8 rear subframe, Quaife ATB 3.06 diff

Had not given this much thought, was going to degree it straight up. Must admit it has been a long time since I have built a performance engine, and this just slipped my mind. Now that I think of it I did run the cam's in my Toyotas, and Datsuns a little advanced. Remember those nice Datsun pickups from the 70's. They were a blast to drive, plus I was a teenager then.....

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1977 240D turbo

Cam came today, so working on it again. Engine is now together, and have started pulling the old one. Did put the cam straight up for now. Want to see what it does before changing to much. With any luck should have it running by the end of friday.

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1977 240D turbo