OM616 engine into W115 body
 

I asked a similar question before, but got mixed, unclear answers, so I thought I'd clarify myself a bit and ask again.
I have a 76 240D with good body and auto trans. I also have a rotted but good-running 83 240D with good drivetrain, and it's a stick.
I'd like to drop the 83 motor into the 76, using the 76 auto trans.
I'd also like to use the 76 motor (already pulled) on the 83 manual trans for a later project.
Aside from the obvious flywheel/torque converter swap, what do I have to do to make this work? I am a welder and good with fabrication, so making and moving mounts and such doesn't scare me. I'm prepared, lay it on me.
Please, no questions like, "why would you do this?" or "you'd be better off with this...". Basically, I look at this project as it is DEFINITELY going to happen, I'm just trying to figure out what problems I'll encounter, and how to get around them. Pretend you're on Monster Garage, what would you do?

I don't know if the mounts are different, but if they are, you should be able to just swap mount arms from one engine to the next (aluminum arm on the side of the block). The other thing to be aware of is the flywheel balance. Make sure that if the flywheel on either engine is not neutrally balanced, that the offset be applied to the one going on. Unless there is some obvious reason not to use the manual tranny, I would just swap the engine tranny as a combo (not sure about clutch peddle mounting though). Overall should be pretty straight forward.

Is the oil filter housing the same on both engines, would that matter?

I don't think it will work due to the oil filter housings. I believe the 616 from the W115 used a diffrent style filter.

If the original 616 is working (you said you plan to use it in another project) why would you swap another engine for it? :confused:

On the 617 engine the crank/flex plate , or the crank flywheel is a match balanced unit. Not easily interchangeable.

I suggest you check to see if this is also true for the 616 engine assy.

Yes, do look at the filter location in the late engine and measure to your 115 engine bay space.

Ok, here's my reasons for using the OM615 in my project and putting the OM616 into the W115...
Aesthetics. Nothing more.
The project is an old hot rod. The OM615 looks like more of a vintage engine, it just has a better look for what I'm doing. I'm not concerned with the power. If I want power, I'll take my '67 Barracuda out for a joyride.
I heard before about the oil filter housing. What if I rigged a remote filter setup? Keep in mind, I'm pretty handy, I don't mind rigging things to work, and I have a god friend with a masters in mechanical engineering who's rarin' to help me on this one. Basically, no matter how hard, even if it involved frame notching, balancing, and machining, we're gonna try to make this happen. I'll try to check on the oil filter housing in the next coupla days.

Filter housing issues aside, just use the original mount arms (for the car)and it should bolt right in.
You will still have to address the balance issue.

Yeah, I think the oil filter housing is the only major issue- if you can get around that you should be smart enough to make anything else work.

Rock on! Sounds good.
Someone mentioned the oil pan possibly hitting? Anyone know about this?
It's weird, I thought this would have been a fairly common swap over the years, to put a later engine in an earlier car. Seems I'm some sorta pioneer or something!
Thanks for all your help!

Hey, one more thing, will the valve cover from the OM615 bolt onto the OM616?

If both cars are 240Ds, then both engines are the OM616. Yes, the valve cover should swap.

Wow, I need to really bone up on my MB knowledge. Please excuse me, these are my first MBs I have ever owned. I guess I had it wrong, the '76 is a 240D, not a 200D, so both engines are OM616s. Does that make the swap easier since I had it wrong and they're both 240Ds? Now I'm thinking on not doing the swap and just using the engine from the '83, with the earlier valve cover and intake, since those are really the only two differences that make the earlier engine look better for my project. Jeez, I feel like I have my head up my arse!

Swapping those parts would be easier. The 83 engine should have more power too.

And it won't have that ridiculous pneumatic governor system either.

I thought the later 240Ds had an intake butterfly...

For the EGR. The W115 models had one to govern the injection pump.

I can't think of any good reason to put a W123 240D engine into a W115 body....too much work. Now if you wanted a turbocharged 617....that's another story, and it has been done (check the archives) but I never saw any details about HOW it was done. Yes, the oil filter housing has to be relocated, and it's a real tight fit on the left hand side where the W115 battery lives. Might have to adapt a different air cleaner too and I'm not sure if the power steering reservoir can stay where it is either.

That said, I wonder how many good, W115-style 616 & 617 engines are still out there....should one ever need a replacement. The cars often rust out or are in wrecks before the engines wear out, but I've been reading too many stories about ruined engines too, these days.

Diesel MB rat rod
 

I remembered seeing this on Youtube a few weeks ago. Awful music but it is an MB diesel in a rat rod:

http://www.youtube.com/watch?v=_nCvjWHGnTQ

Another good video ruined by terrible music playing over what people REALLY want to hear, the engine.

Yeah, no kidding, and he's claiming more than 43mpg? I'm actually hoping to scratch the 50s with mine. It's gonna have the 240D instead of the 300D, be a lot more lightweight than his, have a lot less frontage (more aerodynamic), and I'll be experimenting with the gear ratios as well. Well, you're probably wondering, so here's a krappy rendering of what's in my mind. Older Jeep frame, Alfa Romeo aluminum quick-change rear, aluminum VW buggy coilover front beam, the aforementioned 240D engine and manual trans, Beetle body, chopped/sectioned VW bus roof, Oliver tractor grille. Not much weight here, and with the front end geometry set up right, should handle like a slot car, too.

The flapper and whole concept is cool, but has that guy ever heard of engine degreaser? And 40-something MPG?!?! Phuleesse! :rolleyes:

115 and 123 chassis do use a different oil filter housing, but if you have the room under the hood it should fit. When the 123 chassis came out it was the first or close to the first to use the "new" universal arrangement, alt on right, a/c on lower left, ps upper left and so on. The 115 has different mounts for those devices. I do believe that there are mounting bosses that are missing engine from engine. Trans should mount with no problem. You engine shut off I believe on the 115 chassis is the old mechanical style? You may have to modify your ignition switch to accomodate the vacum shut off or just swap out the pumps.

Bumping an old thread. Where is the link to oil filter housing swap? Thanks