I was just thinking about this today while mentally going over parts I need to order. The project is taking the engine from an 85 300SD, the 38# flywheel, and a 83 240D manual transmission and putting it into a 83 300D chassis with only 103K miles.

IIRC, the oil cooler lines are different on the W126 300SD vs the W123 300D, will I need to use W123 oil cooler lines?

Any other parts that will prevent this conversion from going smoothly? Are the engine mount arms the same?

I have a set of Non-EGR manifolds off of a junk W116 300SD engine, will those go on an 85 engine without any trouble?

Also for the transmission mount, does anyone have the correct part number for the 240D auto mount?

Thanks

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Current: 1975 450SEL, 83 300D, 88 Yugo GVX, 90 300D OM603 swap, 91 F150 4.6 4v swap, 93 190E Sportline LE 3.0L M104 swap, 93 190E Sportline LE Megasquirt, 03 Sprinter, 06 E500 4Matic wagon.

You may need to change the oil filter housing for the lines to hook up correctly. The 240 might not be the filter you need. The pilot bearing will be too big and will need to be reduced a bit in diameter by grinding it down. Hold the bearing on something and put it almost 90 degrees to the grinder wheel so it does not spin so fast.

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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.

Tom got the pilot bearing thing right. SKF PN6202-2RSJ (or equivalent) is available at any bearing house and has a 35mm OD. The engine will have a 34mm hole and there is no commercially-available 34mm OD bearing. If you have access to a drill press chuck up the bearing with a bolt thru the center (so you can grab it) and hold a 4 1/2" grinder (or similar) against the OD. Measure FREQUENTLY until you get just slightly over 34mm so that there's a press fit into the bore. Unless you have access to a lathe, in which case you already know how to fix it!

Other than the chassis you're installing it in this is exactly the swap I did on Mutt the Race Truck. I'm not running an oil cooler so I'm no help there but remember that you can take your OM617 hoses and your 240D hoses along with the distance between the two down to your local hydraulic hose shop (pretty much every town has one) and they can make up whatever you need to get from here to there.

Dan

The transmission mount part number I purchased when swapping the OM617 from an 85 300d into my 83 240d manual car was 123-242-07-01. It's $66 new from the dealer.

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Old Blue - 83 240D 6 speed manual trans, OM648
Green Machine - 2001 Europa G500
87 300SDL Bought on Peachparts. Low-ish miles..?

Family Truckster - 2012 VW Touareg TDI

Patchouli Wagon - 2004 E500 - SOLD
333k mile 97 BMW 750il V12. - SOLD
The Californian - 85 300TD - SOLD
Daily Super Sedan - 03 Audi S8 -SOLD