Starting to lay out the project, would like to start soon. The engine is 603.960 with the turbo and head from .970. Might use the .970 IP also with the full-RPM turned up to .960 specs.

The car is a '95 E320 Special Edition, non-ASR.

Exhaust, driveshaft, throttle cable from '87.

Cruise control not sure, I'm guessing '87 unless the '87 actuator can plug directly into the '95 cruise harness.

Fuel system? I'm hoping I can simply remove the gasser fuel pumps and filter and bypass.

Engine shutoff will be a spare switchover valve: Non-energized = open (vacuum source to shutoff valve). Energized = closed with the shutoff valve side vented. I hope it can handle 100% duty-cycle.

Front (coil) springs = '87 300D springs (I'm assuming that the 603 is heavier).

PS pump = '87

Alternator = '95

A/C compressor? Hoping the '95 will adapt (R-134a).

Radiator and plumbing will be interesting with the different plumbing and locations of items in the '95 car. I'm planning to use the inner-firewall from the '87 passenger-side.

Air filter system will likely be the '87, but I'm not sure how it will work. I'm using the 55-trim turbo from the '91 which doesn't have the ARV (shorter snout). Also, I'd like to eliminate the AFM if possible, that will require a different hose from the air filter to the turbo. Available??
Also, if I eliminate the AFM, will the car's Electronic Idle Regulation work properly? I'm hoping that the AFM is for emissions only. I might install it and weld the flap full-open if I can't solve the intake-tube issue. OTOH, not having an inner-firewall on the right side does leave more space for clocking the turbo and plumbing an aftercooler, ... I will be leaving the fresh-air duct in place that cools the RH engine mount, maybe modifying it for cool air over the exhaust there.

Oil cooler from the '87, hope I can find the inner-fender plastic piece somewhere to protect it (300D only part).

The '95 engine wire harness (new) will be removed and the '87 one installed. Also, the '91 glow-plug harness (afterglow) and relay.

'95 cluster, with '87 idiot-light legends in the right side (glow-plug instead of check engine).

ABS should be unchanged with the car being a non-ASR car.

Any big oversights yet? I'm hoping that this is an interesting enough project to attract the combined knowledge of the board and eliminate some of the pitfalls I might otherwise find while the engine is half-way in the hole.

Oh, another thing: I might be registering it in Fort Lauderdale, FL. Do they have emission testing? Never had a problem with the motorhome (diesel), but do they test cars?

__________________

Gone to the dark side

- Jeff