I'm in deeeep, 2.5Turbo into '93 190E swap. - PeachParts Mercedes-Benz Forum

Jetmugg · #1 06-04-2007, 01:13 PM

I'm mid-way through a swap of a 2.5T engine into a '93 190E. The '93 has a beautiful, rust free southern body which had a bad engine. The '87 2.5T car is a typical northeast Ohio rustbucket which ran great but had the tranny go out and is beyond saving (in terms of the body). What I am trying to create is a '93 190E chassis with an '87 2.5Turbo diesel powerplant.

The nuts-and bolts of the swap are going pretty well. It's the wiring harness that has me worried. Both cars are sitting side-by-side in my garage, with the engines and trannies pulled out of each car. I'm now at the point where I need to start pulling the engine harness out of the 2.5T car and moving it over into the 2.6 gasser car.

Has anyone successfully completed a diesel-into-gasser swap such as this, and do you have any recommendations for how much of the under-hood and under-dash wiring harnesses need to be swapped?

Any and all help would be appreciated.

SteveM.

BioPOWER · #2 06-04-2007, 02:23 PM

I'd guess at least the engine harnesses need to be changed, most likely the computers as well. The diesel has no need for ignition wiring, and the gasser harness will have no glowplug hookups. You'll also need the ignition switch from a diesel, because its vacuum shutoff system is diesel-specific.

Good luck! Are you planning to use the 190's 5-speed manual trans?

chasinthesun · #3 06-04-2007, 02:54 PM

I was hunting for a radiator for my 88 190d at the junkyard,the 2.5 has a special radiator with the trannie cooler opposite of the gassers ,just a heads up when it comes to that install.

jshadows · #4 06-04-2007, 10:06 PM

I did a '79 SD to '79 SD wiring harness swap (one had some bad home wiring job + some burnt and frayed wires...I needed to start with a clean virgin slate). This is not a task i wish on anyone.

Anyway assuming MB has not changed their ways over the years, and I'm pretty sure they haven't, you will have to swap the entire front portion of the wiring harness.

This means everything under the hood and all up front accessories. The rear accessories (lights, speakers, etc.) and the power window wiring can stay intact and is hooked up at various plug points. You'll then have several points to work with.

Left side of engine
Right Side of engine
Dash components (computers, relays, etc)
Console components (ACC, etc.)

Everything will have to come out up front. Dash and center console, probably parts of HVAC to get at interface points for passenger side engine wiring. The other side goes through the fuse box. you'll also want to swap fuse boxes since it's all part of the wiring spider too.

I'd say it's doable in about 2 solid days of work with both cars there. it's not fun and you'll swear a lot.

ARINUTS · #5 06-04-2007, 10:16 PM

Won't this vehicle be a problem with SMOG or any emissions inspection?

Jetmugg · #6 06-04-2007, 10:32 PM

I already have the dash completely out of the '93, as well as the fuse box. I figured that pretty much all of the under hood wiring has to be swapped, except possibly for the horns and headlights. It's like a giant bowl of spaghetti right now, but I was careful to label every wire as I took the cars apart. The entire interior is out of the '93 also. I think that if I'm careful and take my time, I'll get everything done correctly, but it might really try my patience at some points. So far I have resisted all urges to start cutting bundles of wire with a pair of tin snips.

As far as emissions, Missouri just passed a bill which eliminates emissions testing for all pre '96 vehicles. YAHOO!. I'm hoping to get the title changed on the '93 to read "diesel" instead of "gasoline" after I have the safety inspection done, but in either case, it will not require emissions testing.

jshadows · #7 06-05-2007, 08:28 AM

Quote:

Originally Posted by Jetmugg

I already have the dash completely out of the '93, as well as the fuse box. I figured that pretty much all of the under hood wiring has to be swapped, except possibly for the horns and headlights. It's like a giant bowl of spaghetti right now, but I was careful to label every wire as I took the cars apart. The entire interior is out of the '93 also. I think that if I'm careful and take my time, I'll get everything done correctly, but it might really try my patience at some points. So far I have resisted all urges to start cutting bundles of wire with a pair of tin snips.

Sounds like you're 75% there anyway. I doubt you'll avoid the lights and horns. Everything is interconnected with rolls of friction tape (which gets nice and gooey as it ages). They're probably the least of your worries too. I found taking the harness out was much more difficult than putting it back in. Having taken photos helped a lot too for some orientation of the spider issues.

You probably will want to deal with essential vacuum routing before you put the wiring harness in. After it's pretty crowded in there for stringing vacuum lines

SwampYankee · #8 06-05-2007, 01:58 PM

Quote:

Originally Posted by ARINUTS

Won't this vehicle be a problem with SMOG or any emissions inspection?

Would be in CT (a problem, that is). We can only "legally" swap model year or newer engines, too. I'm envious of what some of you guys' states allow you to do.

Jetmugg · #9 06-05-2007, 03:03 PM

My current plan is to start carefully swapping the vacuum lines and wiring harness from the 2.5T car into the '93 while the engines are out of both cars. I'm trying to keep the whole operation as clean and "factory" in appearance as possible. Once the wiring and vacuum harnesses are in place, then I will move the engine, transmission, radiator, air box, etc. into the '93 chassis. The 2.5T passenger's side fender also has to be swapped in order to accomodate the air intake system.

There is currently still a lot of "spaghetti" attached, but I should be able to remove much of the leftover gasser-specific stuff after the diesel harness finds its new home.

Does anyone know of a good source for the zip ties with the integral push-in barbed connectors which MB uses to secure the wiring harnesses to the fenders, sheet metal, etc?

SteveM.

fastpakr · #10 06-05-2007, 03:13 PM

Quote:

Originally Posted by SwampYankee

Would be in CT (a problem, that is). We can only "legally" swap model year or newer engines, too. I'm envious of what some of you guys' states allow you to do.

That's actually Federal law. If Missouri doesn't enforce it now, you're lucky. I wouldn't get too caught up in counting on it for the future, though.

rwthomas1 · #11 06-05-2007, 05:25 PM

I don't know where/how exactly MB places the VIN numbers but the tag on the dash is obvious. If possible swap the '87 VIN numbers to the '93. RT

Jetmugg · #12 06-05-2007, 09:27 PM

I won't be swapping the VIN's. That's too blatant.

I only said that Missouri won't be doing emissions testing on pre-96 cars after August 28th. The MO safety inspection does not include determining the year of the engine and comparing it to the year of the chassis.

Crossing my fingers,

SteveM.