I have a 77 240d engine in my 87 jeep wrangler ( The 240 was shot). The engine was rebuilt in 1991 and has set ever since. When I bought the car it had papers in it for $4k spent 9k miles ago so it should be in good shape. I put a battery on it and it fired right up no problems. I used a 4spd trans (No OD) and a 4.10 ratio with a 255/70/15 (29")tire and it has just enough power to drive it. Not even half of what my old 82 240d with 475k showing has. I want to drop to a 3.73 or 3.54 gear or 31" tire but ti will not pull a 31" tire now. I dont know if I have a problem or if I need to look into a turbo or I was thinking of an eaton M90 supercharger from a 3.8 buick. Also if its cold it takes forever for the old style glowplugs to start it is there a better plug?

You can upgrade it to pencil style glowplugs for a much better/faster startup. Will require a new relay, wiring and ignition switch of some sort (could just do it manually)

You've only got 68hp, so its not going to offer much. A turbo/supercharger is likely not a good idea as the engine was not designed for it. You'd probably be better off with the 617 turbo engine in that setup. Or even a N/A 617, it'd give you an additional 25hp or so....

__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)

No need for any changes to relay, or switches with the pencil plugs. Just screw them in, remove the ground from the plug nearest the front, put jumper wires from plug to plug and the hot wire to the plug nearest the firewall.

Turbo is not going to help that much except at altitude unless you get a new IP with an alda.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Well i am assumeing the 617 is the 5 cyl correct? If so I cant use it because of the oil pan vs frotn axle clearance. I really wanted to go this route I even bought a wrecked 300td wagon to get the engine but there is just not enough room. I would be perfectly happy if this thing would just run like my other one! I think the jeep is at least 500lbs lighter and geared lower than the car is and it doesnt even compare. I put new fuel filters on it when i changed it but i was thinking about turning up the fuel rate because it never smokes at all.

You must get an EGT gauge first before you ever touch the fuel settings. You can burn up the engine very easily by messing with the fuel settings without the proper precautions.

find a turbocharged 617 more reliable that way, since it has pistion oilcoolers and such. it will bolt up to the 4speed tranny just fine.You will just have to make some minor adjustments to things like the mounts and shifter linkage.Youll also have to match the flywheels and get the driveshaft cut and balanced. But, if you want to keep the 4cylinder engine in there i would suggest getting the injectionpump tuned maybie getting the head ported, a more agressive cam maybie? (thats a joke..). new injectors will help if yours are old. maybie propane fumigation? you will gain about 5hp and it will clean up the burn, youll get about a weeks worth of driving time out of a grill can.

PS: you could drysump the engine if you dont have enough clearance thats what should be done anyways right? your rockcrawling.

__________________
Have you ever noticed that anybody driving slower than you is an idiot, and anyone going faster than you is a maniac?

As long as they would add one additional commandment for you to keep thy religion to thyself.
George Carlin (Wonder where he is now..)

1981 240d (engine donor 1983 240d) recently rebuilt engine hurray! - No more.. fought a tree and the tree won.

pearl black 1983 240d 4speed (Converted!@$$%) atleast the tranny was rebuilt.

This is just a street truck not a rockcrawler. I only have a 15" driveshaft now and I can't shorten it any more. Even with a dry sump the front diff would hit the engine if I moved it forward so im stuck with the 4 cyl. I have had a 6.2 chevy and a 6.9 ford that had banks turbos on them with no problems why is it such a big deal to boost this engine and turn the pump up to match? I know you need an EGT but if you have no smoke at WOT your short on fuel right? The 82 model smokes a little at WOT and has twice the power of this thing. The engine has new injectors at the time of the rebuild. I think there is something wrong with this thing but it seems like everyone says it is normal for these to be like this. It would be great to know what was done to my 82 model because it runs great. I really just would like this to run out like a 4cyl jeep and its not even close.

The turbo engines have oil jets under them that cool the piston crown. It's an important feature that takes away alot of heat and prevents the pistons from melting from the additional thermal load. The exhaust valves are also sodium filled, again, to speed up heat transfer and keep them cool.

At the most, you could get an additional 5-10hp reliably out of it with a turbo. More than that and you'll be significantly cutting into it's lifespan.

Lol a 15" driveshaft. If you used a bigger engine you could just directly couple the tranny to the differential!


A 240 diesel is not going to put out as much power as a 4cyl gasser. But it will certainly outlast the gasser many times over.

__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)

With 4.10s and 29 inch tires, even the 616 should have serious mechanical advantage, I'm surprised it doesn't have some balls.

Its not full time 4wd is it?

How did you mate the mbz engine to the 4 speed (manual?) tranny?

__________________
Cheers,
Robert

hmm, im not sure how much this will help but can you capture the way the engine sounds for us real quick? like a minute or so clip reving it and puttig it into gear so we can hear it? that would make a great deal to what we can help you with. As to no smoke, that could mean that your running abit lean, but the questoin is how did it get lean in the first place?

__________________
Have you ever noticed that anybody driving slower than you is an idiot, and anyone going faster than you is a maniac?

As long as they would add one additional commandment for you to keep thy religion to thyself.
George Carlin (Wonder where he is now..)

1981 240d (engine donor 1983 240d) recently rebuilt engine hurray! - No more.. fought a tree and the tree won.

pearl black 1983 240d 4speed (Converted!@$$%) atleast the tranny was rebuilt.

this chart shows you on the 'power' side of your gearing situation

3100 rpm @ 65 mph does that sound right?

http://www.4wheelonline.com/superlift_tiresize.htm


http://www.4wheelonline.com/images/gear-chart.gif

__________________
Cheers,
Robert

I think that the stock tires will be around 25" d. If that is correct, I am getting a calculation showing that the gearing overall effectively is a taller ratio than the stock 240d, is the jeep lighter than a 240d? if it is the gear ratio may not be the problem, if it is about the same weight your gearing may be the issue. I am guessing your jeep is heavier or the same weight.

I would get a diesel specialist to get the fuel adjusted for maximum effeciency before doing anything else.

My gut hunch overall is that you have a taller gearing overall than a stock 240d and are being stifled by that.

Rather than trying to modify the 240 maybe you should put on smaller tires and wheels or change the gearing for more grunt.

Tom W

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

I agree with the gearing, even the stock 2.4/2.5 jeep motor is pretty anemic with 4.10 and stock size tires. I dont think they really feel right until you get to 4.56's

jeep curb weight is dependant on options and aftermarket items. a 4cyl un-optioned SE is around 3100, a 6 cyl Sahara with hard top around 4000 (these are TJ weights but I think they are comparable)

240D is around 3200

the jeep has a ton more wind resistance at highway speeds

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1982 300CD Turbo (Otis, "ups & downs") parts for sale
2003 TJ with Hemi (to go anywhere, quickly) sold
2001 Excursion Powerstroke (to go dependably)
1970 Mustang 428SCJ (to go fast)
1962 Corvette LS1 (to go in style)
2001 Schwinn Grape Krate 10spd (if all else fails)

I drove this thing all day and it seems the more i drive it the better it runs. I also lost the engine fan and mounted an electric. Maby it just needs to be run and cleaned out. The 3100 at 65 seems right. I was doing some figuring and I think it is geared about the same as a 4speed 240 with a 3.69 gear and a 25" tire. Is the 82 240 automatic an overdrive or just 4 speed with 1:1 high?
For the guy who asked how i connected it to a truck trans. I used a T18 4spd from a ford f250 and the input shaft length, clutch splines and even the ford pilot bushig drives right in the merceds crank. I took a 220d bellhousing and had the center machined out to the od of the ford bearing retainer (I turned down the retainer just a little). Then I had the throwout bearing surface turned down to chevy size. $30 machine shop bill took less than 30 min. I took this home and set it on the front of my trans and drilled the 6 MB bellhousing mount holes and tapped them 7/16 (there is plenty of meat in the trans face) Then i bought a howe throwout bearing for a circle track car with a stock clutch. This is the most expensive part was $250 for master, TO bearing and SS braided lines. bolted it all up and it works perfect! This is a very easy conversion and it seems to work very well I just need 4.56 gears to pull 31" tires. If anyone wants more info I will be happy to help out.