603 in a w123 wagon - PeachParts Mercedes-Benz Forum

martureo · #1 03-08-2016, 10:16 PM

1983 300TD Federal

So I've had this wagon for a few years now. Bought it for $800, engine was sitting in the car (not even bolted in). Someone had pulled the engine for a project, couldn't get it to start. So they shoved it back in and sold it, and I bought it from someone who had it sitting for a bit. Great idea, I know.

So I've pulled the engine, degreased the engine bay and painted it. The car was originally Champagne (473) and I'm changing it slowly to Desert Red (Borolorot 540).

I reconditioned the rear suspension and fronts suspension. Every piece of rubber is new, everything was painted. Rebuilt the brake calipers (1st gen w126) and it has a master cylinder from a 300SD.

Pics of cleaning the black engine bay.

martureo · #2 03-08-2016, 10:23 PM

Here's the new paint in the engine bay.

So I eventually got the engine back together (the previous tinkerer had cut most of the wiring harness and damaged/lost dozens of pieces). SLS worked, so I drove it around the block and it smoked enough to kill all the mosquitoes in the neighborhood.

Bottom end problem had me on the lookout for a new engine. But after finding no decent 617s I wanted to pull the trigger on I settled on a 603. Ended up buying a 1987 300TD which was totaled (149,000 miles). We just pulled the engine today.

Impact was to the driver's front wheel. It broke both engine mount arms and smashed the starter. It was hilarious when I tried to start it and my brother in law started yelling because the starter was sparking, jumping around and smoking. Here's a shot of what's left of it.

martureo · #3 03-08-2016, 10:24 PM

New engine home now. I'll update when I fit it in the w123.

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gatorblue92 · #4 03-12-2016, 09:45 AM

Looking forward to seeing this come together.

martureo · #5 03-26-2016, 10:45 PM

Haven't pulled the old (headless) 617 from the wagon yet. Should be getting around to freshening things on the 603 before I get ready to put it in.

I've been pleasantly surprised by a few things related to the instrument cluster. I figured I'd have to adapt a bunch of stuff to the 123 cluster, but it turns out that the speedo cable for my s123 works with the 87 300TD transmission. The only things I'll have to adapt (fingers crossed) is the oil pressure fitting at the filter from electronic pickup to an oil line like on the w123 and the coolant temp sensor pickup.

The cluster from the 87 donor isn't that different than the 617 powered vehicle. Even the tach is the same.

1983 300TD

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1987 300TD donor

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Tach panel on 1984 300TD

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Tach panel on 1987 300TD

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martureo · #6 04-24-2016, 06:54 PM

Because of the great weather this week I finally got around to pulling the 617 (headless) and trans and fitting the 603 for the first time.

From some quick eyeballed measurements I've got 3 inches in the front and four in the back. This does not include the radiator, so I'm definitely going to be shifting it back a bit. (I already planned to have an electronic fan on the grille side of the radiator)

martureo · #7 04-24-2016, 07:04 PM

A few other things I'm going to have to deal with soon.

Old 87 300TD driveshaft on top, 83 300TD driveshaft on bottom.

And the flanges/guibos are different. I think I'm going to end up using the w123 driveshaft, and change out the final drive flange on the transmission.

83 300TD on left, 87 300TD on right.

And then we have the engine mount arms. The donor car arms were broken in the accident so new arms were a given. I attempted to put the old 617 arms on the 603, but no dice. The hole pattern is different.

617: 2.5 in (63.5mm) x 3.875 in (98mm)
603: 3.8125 in (97mm) x 3.125 in (80mm)

[These were done with a ruler and are just rough measurements]

603 on left, 617 on right

Mölyapina · #8 04-25-2016, 10:13 AM

Quote:

Originally Posted by martureo

Old 87 300TD driveshaft on top, 83 300TD driveshaft on bottom.

Are the two driveshafts the same length?

chasinthesun · #9 05-08-2016, 04:48 PM

If I remember right didnt some of those netherland guys build a road killer wagon and a drop a 603 into the engine bay ,the car was a 300td and would boil tires .Ive visited their site for that wagon build and its pretty pic heavy ,you might spot their custom engine mount if the site shows it .

martureo · #10 05-08-2016, 10:17 PM

Quote:

Originally Posted by chasinthesun

If I remember right didnt some of those netherland guys build a road killer wagon and a drop a 603 into the engine bay ,the car was a 300td and would boil tires .Ive visited their site for that wagon build and its pretty pic heavy ,you might spot their custom engine mount if the site shows it .

If you've got the link or a name it'd be appreciated.

I've seen a few 603 w123's on european sites, but only a few pics here or there.

martureo · #11 05-16-2016, 02:10 PM

Quote:

Originally Posted by Mölyapina

Are the two driveshafts the same length?

Almost.

w123 617: 60 inches
w124 603: 62.5 inches

panZZer · #12 05-16-2016, 03:44 PM

Quote:

Originally Posted by martureo

1983 300TD Federal

So I've had this wagon for a few years now. Bought it for $800, engine was sitting in the car (not even bolted in). Someone had pulled the engine for a project, couldn't get it to start. So they shoved it back in and sold it, and I bought it from someone who had it sitting for a bit. Great idea, I know.

So I've pulled the engine, degreased the engine bay and painted it. The car was originally Champagne (473) and I'm changing it slowly to Desert Red (Borolorot 540).

I reconditioned the rear suspension and fronts suspension. Every piece of rubber is new, everything was painted. Rebuilt the brake calipers (1st gen w126) and it has a master cylinder from a 300SD.

Pics of cleaning the black engine bay.

Desert Red, that's the first time I've ever heard anyone else but me call it that color. my 85 window sticker calls it that, earlier yrs the burgundy was called something else.

martureo · #13 08-08-2016, 09:54 PM

Long time no update. The plan is to get it driving enough to get to Chad's GTG up in PA, on the 20th. That's 11 more days to when it needs to be done and I'll be going to the beach from Saturday until sometime Tuesday night. So really, it's 7 more days to get it done.

Here's the list that still needs done.

motor mount arm spacers (final machining tomorrow)
transmission mount (new holes to be drilled)
fit driveshaft (hopefully w123 driveshaft is long enough)
heatshield for battery (bend '85 Cali one to fit)
radiator hoses (make sure proper length after engine shift)
trans cooler lines (make sure proper length after engine shift)
oil cooler lines (finish making AN style hose)
oil cooler bracket (finish making and install)
radiator fan (order after engine fitment)
air filter (no idea yet. Cone filter maybe?)
SLS hard lines (half bent, need flaring done)
fuel lines (finish mounting fuel thermostat)
accelerator linkage (finish bracket for pedal and install cable)
brake booster line (fabricate from old line)
exhaust (cobble together last minute from w123 sedan parts)
cluster signal (tach signal wire reroute. Oil pickup and speedo cable ready)
thermostat (install new)
tires (dry rotted)

It will be a miracle if this gets done. I might be taking another day off work to complete everything.

...or I might drive something else to Chad's. But hope not.

martureo · #14 08-09-2016, 02:11 PM

I finally found a solution to a tricky power steering issue. I'll try to post some pictures with modification updates later tonight.

Simpler=Better · #15 08-11-2016, 03:33 AM

Look at you Mr. Power Steering!

There is a shop in Balamer that specializes in driveshaft work-I want to say they're called A-1 Driveshaft.

Edwards Automotive Machine Shop in Timonium will either be able to do the work, or will know someone who can

x2 on the Efan-my $30 generic one frmo Amazon has been great on my truck