w114 220D with 300TD engine - Mercedes-Benz Forum

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post #1 of 2 (permalink) Old 01-21-2010, 06:53 AM Thread Starter
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w114 220D with 300TD engine

Hi there Folks,

I have had this Benz for 6 years now, it was given to me in trade for some work. And when i got it, most of the floor was rusted out, no air filter on 240D engine, leaked everthing, and had Wall light switches to turn on the headlights and windshield wipers. it was blue, and rusted on the outside, rear bumper was a steel pipe fiberglassed into the trunk, etc. You can imagine as i don't have pics. Since then I purchased 2 w115 and 1 w114 for parts. 2 had the inline 6 dual carbs, 1 had the 2.3 gas engine. Which i sold later. After resortation the first time about 4 years ago, a semitruck hit me front on about 30mph and destroyed most of front end, lights, chrome, radiator, family was fine me too, and engine was fine. Drove car home actually 2 miles away and it didn't overheat! So later. I fixed the mechanical part of this accident and somewhat the aesthetics. I later sent the car to get totally rebuilt, but even deeper this time. we removed all glass stripped down to pretty much wheels and chasis, engine, etc. Painted black, put new front windshield seals, door seals trunk, hood seals, reinforced the front end with square tube where it was smashed up. Had to replace the rear taillights with non-factory one's because 1. i Can't find them 2. they were hideous.

Then I left to the USA to work a bit and bought a 300TD for $450.00 in San Diego, north county area, It idled really bad, and had no power. I bought it anyway. I got home and adjusted the valves and the engine ran like new again no problems. I replaced the filters oils, and adjusted the tranny shifting hard, replaced brakes. Then drove it from California, to Arizona and through Mexico, Guatemala, El Salvador, Honduras, Nicaragua, and to Costa Rica where my family lives. With no problems whatsoever other than bribing Mexican police and the muffler scraping at times on the 2foot tall speed bumps in Mexico. I got between 25-28mpg the entire trip with car loaded!!

Ok so long story longer, a few months later a guy hit me on freeway sending me and the 300D off the freeway into a ditch rolling over and destroying the outer beauty of the car. while car upside down the engine didn't turn off!! Nice! so me and my friend got out the back window kicking it and realized NOTHING at all happend to us! We then ran to the car and with help of other people rolled it over and opened hood shut off engine manually. A bunch a Oil ran into the air filter and intake, But no biggie. After the astonishment of me and friend doing fine ambulance checking us out and police reportg done, the tow truck came. I decided to let the benz extract itself with glory and pride, giving 3 tires flat and whole right side of car destoyed roof crushed, right front suspension and rim pushed into car 1 foot. I checked the oil and it was only at the lower mark which is fine, started car. and backed out of the ditch!! and lined up for tow truck!

However during a period of time before the accident the 240D engine no longer had power to start and needed push starting. I have replaced and adjusted everything possible but it just didn't have the compression anymore to start. So I pulled that engine and was in the process of rebuilding it, I got Deves piston rings, all new seals for everything, lower end journals where fine i ordered bearings matched to crank and piston rod journal sizes. Filters, timing chain etc. I ported the head. checked the cylinder liners and they actually where not worn out that much. But I had 2 cracked Piston rings and probably the reason engine burned oil and lost power. The question is how ? Maybe using either at some piont in time??

Since i had the engine out of the w114 and i had a wrecked but perfectly good 300TD engine, I removed the 300D engine with help of family and friends we transplanted into the w114. I had to cut the base for the engine mounts from another w115 subframe and re weld them 2 1/2 inches foward to line up with the massive 5cyl engine, I then removed the flywheel and clutch assy from the 240D, and installed on the 300D, perfect match. Checked the tranny and starter holes, Perfect match. But the OIL pan, didn't seem to be designed for a w114. So after putting engine in and out about 10 times we got the measurements down, and cut the subframe and squared it and re welded back steel plates over holes. That subframe was about 1/8 inch thick hard steel. So next we got engine in, cut a little more space for radiator/oil cooler to fit, I used the factory supports from the w123, welded under w114, Then after the engine sat in the car we noticed the oil filter housing was laying against the break booster pump. So the only real option due to lack of space was removed the booster and drill and cut new hole about 2 inches further away. this was ok because under the dash is the base and support for the boost all attached together to the clutch and brake pedal. So they basically move in unison.

Next was attaching all the lines and getting radiator to fit. it is currently only about 1/2 to 1 inch away from the fan. since it's a cast fan and not flex steel or plastic it doesn't have a tendency to flex and pull itself forward. After all that installed I didn't have room anymore for the factory battery placement, i had to cut it out to leave room for the power steering pump, Which BTW the lines from the w123 fit right up to my w114 box. And since i owner the car i removed the pump becuase the pump leaked. ( late after starting car this 37 year old steering box didn't leak a drop).

Drive shaft and tranny. A bit of a problem. I needed to adjust the eyelits all the way in and move the levers on the outside of the tranny forward, (since the tranny moved back several inches, ) . I also needed to take the driveshaft to a Machine shop and have them cut on lathe and reweld, we only needed to cut 1 1/2 inches out.

After all said and done, I realizeed the accelorator pedal needed work. and took the one from the w123 and the base for the rubber pivot piont for linkage. and cut a small hole in w114 and placed pedal in same layout and position on w123, needed to cut the linkage bar from engine going back to firewall several inches until it matched.

I relocated the battery try from w123 in the trunk of the w114. With new 00 guage positve cable and the negative i attached to chasis of car. Then with terminal blocks i wired up the engine bay again near started and near factory battery position. Hooked up temp sensor to factory w114 temp guage and it worked. Connected the oil pressure line from the w123 to the back of the w114 gauge. Perfect match.

Glow plugs, overboost, EGR, tach. I used the glow plug relay module from the w123 and connected the 12v powerng the relay to the Pull start factory w114 switch. tach I left unplugged. overboost and ALDA, I removed the ALDA diaphram housing and plugged up the banjoe bolt hole at back of intake on engine, removed all vacumm linkage and valves on top of engine conencting to egr and to auto tranny now not needed. I ran 2 vacumm lines inside car under dash to figure out a shut off method later. (still working on this) I currently use a mighty vac connected to shut off on IP.

The exhaust pipe dropped down pretty much in the same place, with little adjustment I got it to clear the slave pitman arm housing and made sure the heat shield was in place. However I got to the bolt union on the muffler /pipe and needed to leave removed for now until i can remove the pre-silencer as it hits the bottom of the car and no room.

Differential. I used the diff and axles from the w123 on the w114 they bolted right in. I need to use them because i couldn't get above 100kmph or 60mph in 4th, now i can get up to 75mph in fourth crusing of course!!

So all in all mostly factory everything minor mods for engine swap. Lots of headaches and bad words used during the operation, but they where for a good cause. here are the pics. enjoy, i will add more later of swap and cutting, and all.

Last edited by Keevo114; 01-21-2010 at 08:18 AM. Reason: Didn't finish
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post #2 of 2 (permalink) Old 01-21-2010, 08:46 AM Thread Starter
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here they are
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