83 240D engine swap into mazda b2200
 

hey all, newby here. i recently aquired an 83 240D automatic non turbo with lots of body damage from a front end accident. the engine runs strong and full of life, barely any smoke and it doesn't miss a beat while running. so my plans for the engine are, being im a crazy mazda pickup guy, to swap the engine and tranny into a 86-93 mazda b2200 ext cab. being that the car is 4400lbs and the truck is only about 3200lbs i should pick up alittle performance right off the bat with the lower weight. i know the engine is abit of a slug, i just want something reliable, cheap on fuel, and in a b2200 chassis. i do lots of fabrication and have built several custom vehicles in the past.
so my question is i've been reading up and i've heard that the tranny can be adjusted to pep it up a little bit? i've never owned a diesel before but have wanted one forever. any other tips on getting alittle more performance out of this motor? did the 4cyl ever come with a turbo setup on it? thanks

ken

also the rest of the car will be parted out really cheap as i don't need any of the parts beside the engine, tranny, driveshaft, maybe abit of the wiring.

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and a little pic of it running.

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should make a nice little truck....but the engine is heavier. these engine into Jap trucks been done before...all home made swaps.

IIRC there was a turbo OM616, but was not sold here in the US.

You will need the vacuum shut down, or you can make a manually controlled set up. Also grab the GP relay and the "gorilla knob".

The turbo 616 was not manufactured by Mercedes, but is a modified licensed version made by an Indian company.

This '83 240D is much too new to have "gorilla knob".

Be sure to save and sell that interior, it looks to be in good shape.

That looks like a really clean rust free 240. YOu can fix that easier than doing the swap.

The 240 by the way weighs about 3300#.

turbo 240D
 

Seach the diesel performance upgrade site for 240D turbo's, the gist is the straight US delivered motor has too much compression for a turbo and not enough piston cooling. There was an 80's turbo kit that was not successful. We are prohibited from importing the Indian 240D turbo by EPA regs, but I would like to get my hands on the crank, pistons, con-rods, manifolds, and turbo from the Indian unit, particularly as I need my crank turned right now. There is no guarentee the Indian unit would start in the northern US winter, India is a lot hotter than here and low compression low piston volume diesels are difficult to start cold.
On your auto, I would get a couple of needle valves to set up the vacuum for the auto-shifting, other threads suggest 10" closed throttle and 0" full throttle, to be adjusted by how hard the shifts feel in your vehicle.
Biggest barrier is getting a rubber donut transmission output yoke to match a U-joint type driveshaft. I've asked some people that plan converions how they did it, but haven't gotten a response yet. I'm planning to put a 300SD turbo 5 cylinder in a 74 ford F150 pickup. Hopefully you can buy a transmission yoke somewhere, I'd hate to have one machined custom.

hmmm the tag on the door says 4350lbs gvw? unless that means something else.

I got the glow plug relay, one thing im not sure about is the little aluminum box with a lever and a 7 seven wire plug into it?

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as far as engine weight goes, i don't think its anymore than 100lbs more than the original mazda 2.2L.

this vacum shut off you speak of, where does that connect onto the engine? and how does it work?

i noticed that there is a crank sensor on this motor, is that for the models with the tach? this one never had a tach, i wonder if they are just on all of them?

yes i noticed that the tranny doesn't use a slip yoke. being that the truck im planning to use does use a 2 piece driveshaft with a movable center im gonna try and use the first half of the benz shaft with the slip part and get it matched and welded to the mazda middle joint. or use the benz middle joint and get the rear pieces welded together.

anywho, i got the engine out today.

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i figured the tranny would be abit bigger lol

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240d gvw
 

gross vehicle weight is car with 4 porky people and luggage. In Germany many of these cars were used as taxis:See the tv show "the Power of Place", the Berlin episode, shows a beigh car like mine tooling around E. Berlin with a taxi meter instead of an air conditioner vent. My 80 240d Manual was 3640 lb on a truck scale with me in it, about 200 lb of lard. I may have to put a carrier bearing driveshaft in my Ford pickup, 56 ford f100's had them. The vacuum shutoff is an obvious vacuum solenoid on top of the injector pump. My 80 does not have the aluminum box with the wires, nor a crank pickup. Good luck.

hmmmmm, ok well the gvw on a b2200 is 4400lbs, i just went out and checked lol. i wonder if that includes a 1000lbs of load? or more? hmmmmm oh and that box i was wondering about on top of the PS pump is for the cruise control. as is the crank sensor as well.

another thing i was wondering is my trans doesn't have a mechanical kickdown device. it does have this little black box thing sticking out the front passenger side of the tranny. it has a single black with white stripe wire running out of it?

Gross vehicle weight = maximum total weight with a load.

Engine weight on the 240 will be about 485. The benz tranny is pretty light as trannys go.

ok, i think the mazda engine is about 300-350 lbs. shouldn't be to bad.

I believe your aluminum box is the cruis control.

The box with the seven connetor plug is the cruise control module. Probably best left out in your conversion.

driveshaft adapter here, $95.

see the gmbenz thread, pg 5 or 6 for pics of it installed.

yah i'll be removing the cruise now that i know what it is lol.

that adapter isn't really what i need, as i still need a mid slip joint between the engine and steady bearing. thanks tho :)

oh does anyone know what the stock gear ratios would be in my transmission? and the amperage rating on the alternator? thanks again for everyones help :D