converting 1980 240D to 300D how hard is it?
 

looks like the compression is low in my 240D (non-turbo standard) so i'm playing with the idea of converting to 300D (non-turbo) out of a running car with 160k miles on it. the threads i found were converting to a turbo and seemed reather easy. otherwise, i'm going to get the 240D rebuilt. looking for some input. thanks

If you can get all the parts for the 300d including the driveshaft, it shouldn't be a big deal depending on your level of experience.

i've changed the drive train in a 1966 volvo 122, but there was no alterations. the 300d is an automatic. will that make a difference in the position of the transmission? and i'm getting the entire car -might even drive it home.

I feel absolutely awful, as the car in question is the Squash. :(:(:(
I have no idea what went wrong, but Andy sure has been about as classy about it as a human could be!!
I think the NA 5 cylinder swap into a manual tranny 240D is just about the best scenario possible. It remains very easy to work on, and without the turbo lag is just a smoother experience.
Again, I just feel awful about what has happened with the Squash. He is such a worthy platform, and with an NA OM617 would be just about perfect.
I am a slimeball used car salesman......:toilet:

BTW, what year is the 300D? The engine can be replaced without having to break into the AC system. [pics with China engine replacement thread] When I had to replace engines in China I just moved all the AC stuff out of the way and it kept it's charge. That would be very nice since the AC has been redone completely and is full of precious R12. If something does happen where the AC system is evacuated then I have some R12 and it is yours!!

the donor is an '81 300D. i can handel a straight transplant w/o modifications. the post i read keep saying that you have to shorten the drive shaft blah blah. but, where would that put the manual shifter in the car?

Jimmy you have been so nice by lending me a tool and all the info. we had squash loaded down with 3 bikes on the roof, 3 guys in the cab, and all the luggage on the way to houston. i'm just happy that we made it back! but, i do think i would like the extra power of a 300D on the highway.

I agree with Jimmy, Going to a 300, non turbo would be a much less complicated swap and a better match for your 240.
With the manual tranny, she'd have plenty of spunk, and you'd be back on the road sooner.;)

TWalgamuth has a 240d converted to a 300dna with a 5 spd(?). He's the man to give you the info.

The shifter would mount in the same place, but some shortening of the linkages would have to be done, as would a shortening of the driveshaft. [4" from what I remember]
I'm betting your Volvo buddy could handle the linkages [heck, you may have welding skills for all I know] but the driveshaft would need to be done by somebody to maintain balance. It isn't that expensive.
I have a 300D driveshaft over here if you need one to chop up. That way you could leave your 240D driveshaft intact just in case you ever needed it.
I'll be closely following this, and offer any and all help I can give.....:)

You will still have to do all the same things that us that have swapped turbo engines into 240Ds have done: match balance flywheel, shorten and balance drive shaft, shorten shift linkages, swap rear differential (if desired)

How did the 616 loose compression?

thanks again Jimmy. i'm doing the research b4 i diggin in. looks like steve and i are going to put a pilot bearing in the volvo first -hopefully an easy fix.

I agree with this idea... and maybe you could talk Paul out of one of his 5 speeds... LOL

I have done that. It looks like all the steps have been chronicalled here already though.

You need to post a pic when you get that Volvo going. What an impressive 2 car fleet you have. Very eclectic tastes, plus you hang out with a buddy with a 5 sp Turbo Volvo coupe! Awesome!!
:thumbsup2:


Paul's nice, but he ain't that nice....... :D:D

looks like i'm going to test drive 300D non-turbo parts car on sunday. how messed up is that? thinking it's $800? seems like an okay price for a driving parts car.