Haven't been on for a while..but thought I'd ask after a search this morning.
I have a buddy doing a swap of a 300 mb turbo diesel into a nice 240d manual car.
He is not a member of the forum yet but he needs some info and some parts so I referred him to peachparts. We need some Links on the Conversion.
can you post any links that you think will help in his conversion. He is doing this swap outside in a cold Utah winter.
a.What about the witness marks on the crank -flywheel
b. tranny mount suggestions
c. linkage info on cutting and welding
d. does he need to change the rear end ratio?
e.. anything you might feel would help the swap
go together smoother.

He was first going to try to turbo the 240 but since picked up a 5cyl motor of a mid 80's 300td.
240d motor is out and the 5cyl ready to go in. I told him to hold off pulling the flywheels until I posted here.

Thanks and I'll forward this to him and monitor as things are posted.

Thanks in advance.

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81' 240d 4 spd 140k on the clock

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81' 240d 4 spd 140k on the clock

I hope these help you.

http://www.peachparts.com/shopforum/diesel-discussion/146636-w123-240d-engine-swap-om617-300d-manual-transmission-swap.html


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you will need a pilot bushing made for the 617... also, the flywheel, and shifter linkage need to be shortened about 4" AND you need a transmission crossmember from an auto 240D...

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 560SL convertible
1987 190D 2.5-5SPEED!!!

1987 300TD
2005 Dodge Sprinter 2500 158"WB
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

He will want to swap the diff too otherwise he will get poor mileage and the motor noise on the highway will be too much.

On the flywheels, the witness marks on my 280e were so faint as to be nearly invisible. I suggest marking the FW before taking it off the engine, then checking for balance. If both are neutral you are good. If one is not neutral the new FW for that engine needs to be match balanced to the fw which came from the factory on the engine you are using.

Most Fw are neutral but the results of a non neutral engine getting a neutral fw will be disasterous so best to check.

Good luck!

I am getting ready to do a 3 liter turbo swap into an 82 240d myself right now.

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

I finished mine swap this summer. There is a lot of work to do, but basically it is engine out, a few changes, (some new parts like engine mounts,ect) and engine in. The standard pilot bearing (from the 240D - but a new one) works in all the 617's except for the 85 model year. It should gently tap in. If you have an 85 engine, I found it will still go in on a hot day if you put the bearing in a deep freeze overnight and quickly drive it all the way in with a good HD deep socket pushing it in. Your shift rods will need to be shortened by 4" inch. Since the factory thread is a rolled on thread, I would attempt to cut the four inch section out of any straight piece. It takes two cuts with a hack saw and one weld and is very easy. Finding the correct cross member can be a problem, though I found one the first time I looked for one at the P & P. It is the cross member from the 240D automatic which you need. It makes it much easier to do the job if you have two complete cars to work from, a 240D four speed and a 300D automatic. I parts my 300D out at the same time I pulled the engine from the 240D. I still threw away a little more then I should. I used the radiator and oil cooler from the 300D and put on new oil hoses. You can "usually" get the oil line out of the cooler if you are very careful. The front section of the drive shaft will have to be "expertly shortened". A good shop will cut out the four inches, machine a very tight fitting short piece of tubing to insert inside, press the piece together and re-weld. If the job is neat and very clean and consistent with the welding I see no need to balance it. But it could be a problem! The same with the 240D flywheel. I had no reference as to how the flywheel was mounted on the 240D, I could find no marks on the flywheel, and I just remounted it using all new and expensive stretch bolts. They are designed for one use only! But we put the flywheel and clutch on and we have no balance issue. Again, it could be a very nasty problem! Very important to use a torque wrench on many of these critical bolts. It is a must! If you don't have one, buy one. If you plan to use the heater on the 240, you have to get a new heater hose from the engine to the firewall. The 240D uses a very short almost S shaped hose from the back of the engine. However, with the added length of the engine, that hose and fitting would be right against the firewall. So I took the fitting from the back of the 240D head and placed it in the the threaded hole in or toward the front of the head on the drivers side where the temp sender went to the exhaust manifold side. The 2nd or rear temp sender is for the gauge. The hose feeds through the injection lines, makes a 90 degree turn and goes back to the heater. It is a great time to clean up the engine compartment, the PO on mine had painted it all black with some type of undercoat, whew what a mess, but I got rid of all of that. Also, check under the battery tray, make sure you have no corrosion started there, also a great time to check the bushings in that control arm that run across the back of the engine compartment. You will have to use the exhaust from the 300D of course. If it is all rusted out, better look at replacing it. I found one like new from a forum member and traded him my transmission from the 300D. Sometimes luck is the best thing we have going for us. If you are going to use the 300D cooling system, then you will have to install the recovery tank and brackets to the right side inner fender. I junked mine and had to buy one from a forum member. The change of rear diffferential is an absolute must. If you left that 240D RA in there with the 617Turbo, you would feel like you are driving a Mack Truck tractor. It would be all wind up and no go, a real stump puller! At the same time you get or pull the differential, save the axles even if they need repair. If you have to open the diff to get the axles out, make sure you save the " C clips" , and immediately put the cover back on and tape the axles openings closed to keep that baby clean. Dirt in that diff is a disaster.
Then of course you would want a speedometer that would match the RA and get that or save it also. And I would think it should go without saying, but if that clutch and pressure plate don't have the look of real new to it, it better be replaced because the 617 turbo is all that the clutch can handle, probably is more than it can really handle.

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Junqueyardjim
Christianity, if false, is of no importance, and if true, of infinite importance. The only thing it cannot be is moderately important. C.S. Lewis



1983 Mercedes W123 240D 4 Speed 285,000 on the road with a 617 turbo, beautiful butter yellow, license plate # 83 240D INDIANA

2003 Jaguar Type X, AWD. beautiful, good mileage,
Mom's car, but I won't let her drive it!

This first one I posted on bleeding the clutch, there are many threads on this issue.

secnd one has some good pictures.

http://www.peachparts.com/shopforum/diesel-discussion/249874-clutch-bleeding-300d-4-spd-manual-swap.html

www.peachparts.com/shopforum/showthread.php?t=206755

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works