I'm in the process of doing and engine swap in my 300D.

I've begun frantically disconnecting everything connected to the engine. Is there anything that I could possibly miss? This is the first time I've done this.

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-1983 VW Rabbit LS Diesel (5speed, VNT/Giles build)

Oil pressure line, ground strap, alternator wires, Vacuum shut-off line,...

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

as many engines as I have pulled and put in, even in the same car sometimes I always seem to miss something. Dont get in a hurry just move it an inch at a time and watch for things. even if you have everything disconnected things have a way of snagging and getting broken if you move too fast.

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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)

On the first one I did, the oil pressure line wouldn't come out (12mm) of the filter housing so, being in a hurry, I cut it. Big mistake, new one was $50, next time I cut it lose at the instrument cluster.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

already went through a brake booster line, same way...



ground strap...yep, woulda forgot!



anyone else have and swap experiences?

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-1983 VW Rabbit LS Diesel (5speed, VNT/Giles build)

I'm doing this on my 300D too. PS lines, vacuum pump, fuel lines, exhaust pipe, flex disc...

My Haynes manual actually came in very handy for this. I don't trust myself to think of everything that needs disconnecting.

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1995 E300 200k
1981 300GD unknown km

Pretty simple on the old diesels. I missed the ground strap on my first one, just go slow.

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Gone to the dark side

- Jeff

it's a 92 (w124)



little more cramped in the bay...





Radiator and shroud are pulled. Flex disk and mounts by the end of the week.

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-1983 VW Rabbit LS Diesel (5speed, VNT/Giles build)

This link might help: http://mb.auto.pl/wis/w124/CD01/Engine/602_603/01-2400hx.pdf

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DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

My first pull was my '87 300D/124, one more cylinder than yours, but it went okay with the trans attached. Be sure you have a cherry-picker with a lot of lift to get over the radiator shroud, the car will need to be up a foot or so to clear the tail-shaft.

Pulled a 603 from a '91 SDL today, spent about 8hours from start to finish including chatting, lunch, and running home for tools. I cheated though, cut the radiator top brace out.

There just isn't that much attached to these engines, not like pulling a '90s Japanese gasser. Take lots of pictures and make lots of notes, the difficult part is when you have the engine back in the hole and aren't sure where a vacuum line goes.

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Gone to the dark side

- Jeff

THANKS!

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-1983 VW Rabbit LS Diesel (5speed, VNT/Giles build)

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DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

fan shroud and radiator are removed


cherry-picker is far larger than needed.

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-1983 VW Rabbit LS Diesel (5speed, VNT/Giles build)

Large is good, extend the legs and boom, the extra lift is good to have. Do you have a "leveler" so you can tilt and level the engine as you pull it? I didn't on my 124, big pain as the engine came out at about a 30*-40* nose-high angle to clear the transmission, but then to get the tailshaft over the radiator upper support it had to go sky-high. A leveler would have saved me some grief.

The inner-firewall aluminum shroud on the passenger side is good to have out, gives better access to the exhaust. Easiest to remove the flex-pipe from the turbo, the exhaust gave me more trouble than anything, next most was getting the driveshaft free from the transmission. Watch for those transmission wires!

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Gone to the dark side

- Jeff

I will have a leveler or whatever you call the tilting attachment for the picker.


I'm NOT looking forward to the flex disk, as I dont have a car lift and I hate working upside down...

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-1983 VW Rabbit LS Diesel (5speed, VNT/Giles build)