1967 230S 6 Cylinder Gasoline To Diesel Swap; What Is Compatible?
 

I own a 1967 230S fintail with a 6 cylinder gasoline engine and a 4 speed column shift transmission. The car is in good condition and has all new brakes and tires.

Unfortunately, the engine is cracked and has holes in the block, along with bent valves. I am not much of a fan of gasoline anyway, and I just happen to have a spare 617 5 cylinder turbo diesel engine. I want to install the turbo diesel engine into the car and use the original 4 speed column shift transmission.

I have seen this done before, only the automatic transmission was kept on the 617 engine and the driveline was shortened to accommodate: http://fatfranz.wordpress.com/ . It looks like I will have to alter the engine crossmember slightly for the engine mounts/shocks to fit, and I will also have to relocate the oil tower.

The challenge is going to be getting the turbo diesel engine that currently has an automatic transmission bolted to it to fit the 4 speed manual transmission in the car.

What bell housings will fit the 617 diesel engine? Can I bolt the standard transmission to the automatic bell housing? Will the 617 engine bolt up to the gas engine bellhousing?

At the wrecking yard there is a 1969 220D with a 4 speed standard transmission. Will this bellhousing bolt up to the 617 engine?

I am trying to figure out what parts I need to successfully bolt the 617 engine to my 4 speed column shift transmission. Any help is GREATLY appreciated!

Also, I think I may have to change the rear end to taller gears. How hard is it to change gear ratios? I wonder if the swing axle style rear axles ever came with the gear ratio I would need. I imagine I the gearing of the transmission should be fine. Here are some pictures of the car (I saved it from the wrecker):

man, how do you keep finding those good looking finnies? That's two you've posted pics of in as many days!
It would be slower but a 616 might be an easier fit for a diesel swap, and keep the manual trans. Of course you already have the 617.

If someone gave me $1,000 I could probably come up with another 4 or 5 fairly decent fintails. They are everywhere in Washington state. I know where I can get a blue 220S that might fire up and drive away with some work. The original blue paint is a little oxidized but might come back with some cleaning and wax. It's for sale for $300 at the local used car lot.

I passed on a running and driving fairly nice 220S with the Kuhlmeister AC for $300. There was a non-running 200D that had been setting a while, but had 34,000 original miles (original owner had hardly ever driven it) for $450. Then there was a guy selling a running and driving 200D with several new parts that came with a gasoline parts car $500 for the pair--not sure if he still has them. Then there was a running and driving 200D for $250 up north. I also saw a restored 200D sell for $800 here. And currently there is a running and driving 200D that has a rusty fender, but comes with a new one for $850. Most of these cars have minimal rust.

Washington state is the place to buy vintage Mercedes. They just don't sell up here. I almost bought a MINT condition 1975 450SEL that only needed a new fuel pump for $350. It had Euro headlights and wheels, new tires, and the car looked brand new.

If only I had the space to buy all the good deals I come upon... But check out the Seattle, Washington craigslist: http://seattle.craigslist.org/ . You will be blow away at the good deals. Just as long as you don't mind making a trip.

I am guessing I can use a 1979 300SD 617 turbo diesel engine + a 1969 220D or maybe a 300D 4 speed manual bellhousing and flywheel, + a 1967 230S 4 speed manual column shift transmission inside a 1967 230S fintail? Any confirmation?

Very cool project

Seems that the 722.0, 722.1, 722.2 transmissions (Four bolt pan, four speed) only started production in 1970.

Mate the engine with what it came with originally, you'll probably have to custom fab a driveshaft and cross-support to hold the tranny.

I'm GUESSING then that if your vacuum modulator is mounted on the rear of the bellhousing, it will fit. Confirm?

After searching the forum, it appears any bellhousing, flywheel, and clutch from a 220D, 240D, or 300D will bolt up to the 617 turbo diesel engine. Now... will my 1967 fintail 4 speed bolt up to these bellhousings? Is the 4 speed on the fintails the same as the newer 220-300 diesels?

SUMMARY: I need to mate a 617 turbo diesel engine (came with an automatic transmission) with my original column shift 4 speed manual transmission. I think putting a flywheel, clutch, and bellhousing from a 220D-300D in between will work.

Are you suggesting I try to bolt the 617 engine directly to the original 6 cylinder gasoline bellhousing of the 230S? I wonder if it would work, though I would still need a neutral flywheel from a manual (diesel?) engine since the 617 has a flex plate and the flywheel on the original gas engine is counterbalanced.

I'm not sure where my vacuum modulator is right now. I thought a vacuum modulator was only for automatic transmissions?

Oh, manual? I should have read harder.

My information was regarding automatic transmissions.


That being said, there is nothing to stop you from trying to fit the two together.

I don't know, myself I would keep the automatic since you have it. As the 617 more than likely has a different length than the original engine, and thus will move your transmission tailpiece requiring a custom/extention to the original transmission mount and driveshaft modification.

I would not be surprised if the 617 would bolt right up to your manual box. Other than that and relocating the oil filter housing you would have to: possibly make a custom driveshaft, possibly modify the shift linkages, custom make engine mount arms, get a flywheel from a 240D and have it match balanced to the flex plate on the 617, confirm that you won't need a custom clutch/pressure plate.

Sounds like a good project.

The 5 cylinder diesel 617 looks like it is the same length as the original 6 cylinder, so there should not be much difference between the two. I already plan on relocating the oil tower, getting a proper flywheel, altering driveline and linkage length, and custom mounts.

It may be easier to keep the automatic transmission on the 617, but I want this car to have a manual transmission for increased speed and fuel mileage. I think the column shift is way cool. I also want the car to look original even though it's not.

I will see if the 617 fits the original 230S bellhousing when I get to pulling engines. I wonder if it's the same bellhousing that the 200D fintails used--and if so--if it's basically the same bellhousing the later 220D's used, which I believe is the same as the 240D's and 300D's, which bolt up to the 617.

I have wanted to do this for a long time, and the car and engine I want finally fell into my paws one day. Now I just need to make it all work!

By the way, the car will be rebadged as 300SD Turbo Diesel. Haha! I may even go the intercooler route like they did with the car here: http://www.peachparts.com/shopforum/showthread.php?t=220405&highlight=hotrod+220d .

I want to add double emphasis on MATCH BALANCE of the original 617 flex plate to the replacement flywheel.
Failure to do this may result in unbearable nasty harmonics.

It did in mine.

Unlike when I did the successful auto > manual swap in the 240D :) , the 617 auto > manual swap achieved no better mpg. :(

looks like a go to me
 

I just checked on the "Russian Site" for part numbers and I see that the engine rear end plate which is screwed to the block is the same on the 220SB and the W123 300D. Part number is 6150110245 for both of them. That means that anything that attaches to the rear of the one engine will attach to the rear of the other.

YES! So, basically the 1979 617 turbo diesel engine should bolt right up to the 1967 230S bellhousing? I sure hope so, that would be great!

I will be sure to find a proper flywheel and have it match balanced to the flex plate; no sense in getting it put together only to have to tear it apart again.

You should get use to this site
 

This "Russian Site" of part numbers and parts pictures can be invaluable when you are trying to "mix and match" If you are not use to it, when the car model you click on does not come up and you think it is a blank page, just scroll on down and you will see it. I find it so much easier to use then Mercedes EPC. Find it here. http://www.detali.ru/cat/oem_mb0.asp?TP=1