On Sat, 21 Mar 2020 11:38:26 -0400 Michael Esh via Mercedes
<mercedes@okiebenz.com> wrote:
I converted a '82 240D from a four-cylinder engine with an automatic
transmission to a five-cylinder naturally-aspirated engine with a manual
transmission at the conclusion of my grad school stint. I was fortunate
to have a 123.123 Euro car on hand at a nearby salvage yard from which to
get parts. I chose the naturally-aspirated engine because I wanted simple
and did not want the complication of a turbo engine.
> will the 240D transmission matchup to 300D without modifications or
> performance issues?
It should bolt up straight away. If it does not, there is a "plate" on
the back of each engine to which the bellhousing bolts which you can take
from the OM616.912 to bolt onto the OM617.952. That is referenced in the
list below as 110 011 15 45.
> The 240 has manual HVAC that I want keep.
Yes, the sensible thing to do! That was one of the benefits I had when I
turned the 240D into the 240D/3.0. I did the swap primarily, though,
because the 240D automatic transmission was severely damaged deep inside
and I thought the OM616 was weak as well. I didn't want to spend $2500 to
have Ben's Workshop in Austin, TX replace the transmission and still have
the OM616.
Craig
P.S. The list of part numbers I developed (with a terminal "R" meaning
I bought the part from Rusty and a terminal "D" meaning I bought
the part from the Mercedes Dealer in Austin) is:
Lock lube 001 989 26 51 10
Key Blank Head 000 766 44 06
R main fuel filter 001 092 05 01 R
main fuel filter o-rings 007 603 01 81 01
inline fuel filter 001 477 79 01 R
oil filter 617 180 00 09 R
oil filter cover stem o-rings 015 997 94 48 R
air filter 001 094 95 04 R
Vacuum line oil trapping filter 000 078 06 56
Steering damper 000 463 51 32 R
617 engine shock absorbers 123 240 09 48 R
617 transmission mount 123 240 25 18 R
617 motor mount 123 241 30 13 R
617 engine shock weld bracket, left 123 620 13 14 D
617 engine shock weld bracket, right 123 620 14 14 D
617 engine lower oil pan 115 010 04 28 R
air cleaner mounting isolators 617 988 01 11 D
617 improved crankcase ventilation hose 617 018 01 82 R
617 manifold gasket 617 142 07 80 R
exhaust manifold to tail pipe bolts 304 017 08 53 D
exhaust manifold to tail pipe nuts 000 990 32 50 D
water pump 110 200 17 20 R
power steering pump mounting bolts 304 014 08 09 D
power steering pump mounting bolt washers 000 137 08 204 D
tail pipe hangers ("rubber donuts") 124 492 00 44 D
prechamber 616 010 01 52 R
prechamber seal ring 615 017 00 60 R
injector nozzle plate (seal) type 1 617 017 03 60 R
" " " " type 2 601 017 00 60 R
injector return line 615 476 03 26 D
injector return line plug 403 070 00 55 D
injection pump mounting gasket 616 074 00 80 R
large banjo bolt copper seal ring N007603014405 R
small banjo bolt copper seal ring 007 603 012 111 R
fuel pump/main filter plastic hose w/banjo fit. 615 070 42 32 R
inj. pump/injector return plasic hose w/banj.ft 615 070 56 32 R
inj. pump plastic fuel hose w/banjo fittings 615 070 40 32 R
diesel fuel return 007 997 16 82 R
engine plate (to which bell housing bolts) 110 011 15 45
manual transmission pilot bearing 115 980 01 15 R
manual transmission flywheel-to-crank bolts 615 032 05 71 R
615, 616 stick-shift flywheel 115 032 06 01
617 stick-shift flywheel 617 032 00 01
clutch disk 010 250 34 03 R
clutch pressure plate 004 250 32 04 R
clutch throw-out bearing 000 250 55 15 R
clutch slave cylinder 001 295 68 07 R
clutch slave cylinder to bell housing gasket 110 138 41 30 D
clutch master cylinder/brake reservoir tubing 009 997 38 82 D
Transmission tunnel hole plug 000 997 40 20 D
Bellhousing inspection hole plug 617 014 04 33 R
clutch switch to cutoff cruise control 004 545 18 14 D
clutch switch mounting nut 000 439 08 213 D
clutch switch mounting lock washer 000 137 08 212 D
clutch switch bracket 123 545 21 40 D
clutch switch bracket mounting bolt 304 017 06 16 D
clutch switch bracket mounting lockwasher 912 004 06 102 D
clutch switch bracket mounting nut 304 032 06 04 D
driveshaft flex disk bolt self-locking nuts 124 990 14 51 D
driveshaft flex disk kit (w/bolts & nuts) 123 410 00 15 R
bushings on transmission shift levers 000 992 10 10 D
bushings on shifter levers 210 992 00 10 D
Fuel tank strainer 123 471 00 35
Fuel tank-to-body seal around strainer 123 471 11 80
Fuel tank-to-body seal around return and vent 123 471 20 80
Spare tire well drain grommet 107 997 27 81 D
Spare tire well plug 000 997 40 20
Differential axle shaft seal 003 997 83 47 R
Differential pinion seal 014 997 49 47 R
Rear axle half-shaft crush washer 115 357 06 75 B
Instrument panel plastic cap 123 998 00 35
80A glow plug fuse 000 545 03 34 D
fuse pack 124 580 00 10 D
card of 10 white (8 A) fuses 000 545 82 34 R
card of 10 red (16 A) fuses 000 545 83 34 R
Driver's door vacuum master switch 116 800 04 73 R
Fuel door vacuum element 123 800 25 75 R
Right brake sensor cable 126 540 82 07 R
Door striker driver's side 123 720 01 04 R
Door striker passenger's side 123 720 02 04 R
Door striker mounting bolts 116 990 00 31 R
Front door check strap 123 720 05 16 R
Tag off heater blower 123 820 15 42
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