I have a project in my shop, with a 240D 4 cylinder with manual/clutch to a ford top-loader in a YJ jeep.
It is a bit anemic.
Will the 5 cylinder from a 91-93 300D adapt and use this same flywheel?

Wayne

I'm assuming, which is usually a bad thing here, that your 240d was a w123 (1985 and older)

I don't know about the 91-93 which would be a 602 if I'm correct?

but I do know that flywheel will bolt up to a 617 (5cyl 3.0) of the same era, but mark and check the balance of the flex plate and flywheel first, if they aren't a match then you'll have big issues

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1982 300D (w123, "Grey Car")
1982 300D (w123, "Blue Car")
2001 Ford F150 "Clifford" (The Big Red Truck)
1997 Dodge Ram 2500 12V Cummins
1996 Dodge Ram 2500 12V Cummins
Previous Vehicles:
1995 E300D, 1980 300SD, 1992 Buick Century, 2005 Saturn Ion

... and the starter is on the driver's side on the 60x engines.

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Gone to the dark side

- Jeff

The flywheel may bolt to the 602, but the bell bolt pattern is way different. For one, the starter is on the opposite side. If an adapter is available for the 60X engines to your trans, then worst case is you would have to find a FW from a 190D/E 5 speed car.

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All Diesel Fleet
1985 R107 300SLD TURBODIESEL
2005 E320 CDI (daily)

LOTS of parts for sale!


EGR block kit
http://www.peachparts.com/shopforum/diesel-discussion/355250-sale-egr-delete-block-off-plate-kit.html

1985 CA emissions 617 owners- You Need This!
Sanden style A/C Compressor Mounting Kit for your 616/ 617 For Sale + Install Inst.

Sanden Instalation Guide (post 11):
http://www.peachparts.com/shopforum/diesel-discussion/367883-sanden-retrofit-installation-guide.html

To avoid headache, I'd try to source the correct flywheel unless you can verify the dimensions are the same or modify everything so the set up works.

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'84 190D 2.2 5MT (Red/Palomino) Current car. Love it!
'85 190D 2.2 Auto *Cali* (Blue/Blue) *sold*
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I don't think it will bolt up.

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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.

With enough time and money, I'm sure it could be done!

An easier solution to your power deficit would be a 5 cylinder 3.0 liter Mercedes turbo-diesel engine from the early 80's (OM617A). That will use the same flywheel (sort of - it is a bit light but many have used it without issue) and bolt up with no modifications to the transmission that the OM616 was bolted to.

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Respectfully,
/s/
M. Dillon
'87 124.193 (300TD) "White Whale", ~392k miles, 3.5l IP fitted
'95 124.131 (E300) "Sapphire", 380k miles
'73 Balboa 20 "Sanctification"
Charleston SC

what is the setup you have for conversion plate between the engine and trans? I don't think the flywheel bolt pattern is the same. the 616 motor uses an intermediate plate that your conversion may have dropped... unlikely it will bolt to the 602

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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 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Pictures would help. I'd either go with an OM617 or turbo the 616 and get a pump from Dieselmeken - the 616 ought to make lots more power than you'll need if you do that. I don't know how much room the Jeep chassis has for the 5th. cylinder on the 617 but it WAS a tight fit in my S-10.

Other than working out the length, the 617 would be basically a bolt-in in place of the 616. You might need a tad more radiator and you'll have to move the mounts to fit where you need them - current location might be OK. IF you can keep the trans where it currently is the clutch linkage, etc. can stay as it is making the swap that much easier. If you can move the rad forward about 8" or so the engine ought to fit in the space from the bellhousing forward. I don't run the engine mount shocks and have had no issues with that.

BTW - a stock 617 turbo is more or less 125 HP and can be modified to considerably more if you get power hungry later. It sure is worth considering.

Dan

WAYNEB, is your jeep like this one?
1964 Jeep CJ6 with Mercedes Diesel Conversion - $5000 (Lake Elsinore


https://inlandempire.craigslist.org/cto/5519294931.html






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

This setup has already been running with the 4 cylinder, and the HP comments are right. 71 HP and it was anemic. Have a 5 cylinder manifold and turbo with #5 blocked off, but that still won't be enough power, plus the 4 cylinder is noisy.

But here is the real problem. I have the 5 cylinder from a 93, and another from a 92 on hand. That 125HP would be perfect.

The older 5 cylinders is a super-tight fit. I have ruled that out.

Wayne

I have had this project in my shop for 5 years or more. It is at the bottom of my projects list and even if I get it running, I would not drive it.

I have a better project 1968 Bronco, rust free with a 4BT running with automatic, I want to convert to 5 speed. Parts on hand. The Bronco is my favorite 4 wheeler ever. I have had this one converted to diesel since 2004, but never really liked the automatic.

The jeep is dead weight.

Someone want to make me an offer?

Wayne - In Land Speed we call that "ballast". Might be worth more if you offered it as ballast rather than dead weight.

Just tryin' to help........

Dan