240D engine into a 220D

[Newguy]

OK guys, I'm sure that this subject has come up in the past, but I searched and couldn't find it.

I'm considering purchasing a 1981 240D that has body damage and swapping the engine into my 1969 220D. Does anybody have experience with this swap?

What problems could I anticipate?
Will I have too much power for the 220D transmission?

[dbn1066]

I've been wondering about this myself. As far as too much power, I don't think you'll have to worry as the 240 has but maybe 10-20 more hp and comperable torque (anyone correct me if I'm way off). They are basically the same engines that went into the 115 240D if I'm not mistaken. The 123 240D engine should match right up with the 220 tranny, right? I'll follow this thread as I may attempt the same swap.

[Mike D]

The blocks are the same. If the oil filter is the upper canister style such as the 300D then you'll need to modify the supports from the firewall to the fender.

Oil pressure and temperature gauges will have to be converted. Maybe not oil pressure if it's still the manual feed line style.

4 speed? Use the old flywheel. You MIGHT need to change the front driveshaft.

You need to convert the glow plugs to the pencil style control. You already have the box on the '81. Run a 8 gauge line to power it.

I think I had to change out the alternator and bracket to the newer style. Seems to me the A/C mount needed to be changed.

You need to replumb the vacuum lines for the shut-off and replace the ignition switch to the 123 style.

Are the batteries on the same side?

[t walgamuth]

no the 115 battery is on the drivers side up front on the fender. the 123 is on pass side against the firewall.

tom w

[Mike D]

"no the 115 battery is on the drivers side up front on the fender. the 123 is on pass side against the firewall."
Thank you, Tom.

In that case you need to fab up the air cleaner. Junk out the old oil bath and install a good high volume paper filter.

[t walgamuth]

i am not following the air cleaner comment.

tom w

[Mike D]

It's been 10+ years since I did this change so I'm trying to remember how everything went. I think I had to change the air cleaner system because I didn't/couldn't remove the passenger side support strut or I changed over the intake. Can't remember for sure.

I think I had to change the oil pan and pick-up tube also.

Lots of peripheral stuff had to be changed. Got another 5 or 6 years out of the old ride. Man, I miss that old 220D. Some lady parked her Camry in its trunk one day at a stoplight.

[t walgamuth]

i think switching the intake might be a good idea.

tom w

[psfred]

Won't fit -- the oil filter housing on the 616 engine and the upper control arm pivot (and the brace from firewall to spring tower) occupy the same space.

This will only work if you can find a remote oil filter housing adapter, they were used on a couple of models.

Peter

[Newguy]

Thanks for all the information guys. I need to really consider whether or not I want to tackle it, with that much modifications required.

[Mike D]

Well I wish I could tell you an easier way but when they went to the W123 they modernized a lot of the peripherals. They are the biggest pain in the swap.