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post #11 of 20 (permalink) Old 11-30-2013, 04:38 PM Thread Starter
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Date registered: Feb 2010
Vehicle: 1983 240D, 1974 240D
Location: RI
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Originally Posted by LWB250 View Post
Is that motor a turbo motor to begin with? If not you're looking at some serious engine issues if you try to turbocharge it…. like burned pistons, to begin with….
yup, its a pre EGR turbocharged 300SD 617 motor, so it has the sodium filled valves, oil jets, and so on. The motor is 6 years newer, so I had to do some serious work to make the newer injection pump fit in there, essentially cut out the braces to the front fenders, cut the subframe to fit the oil pan, mount new engine shock points, there was a lot of work. Battery tray had to be cut out to compensate for the power steering, later engine oil filter had to be removed and a remote filter has to be used, and so on-

Ill recreate that differently later though, as those braces no doubt have some structural importance to the vehicle if MB had them on there.

here are a couple pics of the later motor issues that needed to be resolved-
subframe notch-



battery tray removal-



Engine shock tab welded-




Here is how the new motor looks from the front, its a tight fit with all the later accessories-


1983 240D 4-speed, DD
1974 240D turbo 617 swap, W201 5-speed project
Abomination Chevy Astro, 616 turbo swap, T5 5-speed, 4.56 diff. Work van

Last edited by JBG3; 11-30-2013 at 04:49 PM.
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post #12 of 20 (permalink) Old 11-30-2013, 04:39 PM Thread Starter
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Date registered: Feb 2010
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Originally Posted by clownracer View Post
Great build! I want a turbo 300 motor so bad!
thanks!

Me too, the 4cyl early 616 wasn't doing it for me anymore, but I love this body style, so im attempting to build a good highway car out of it with a decent turn of speed.

1983 240D 4-speed, DD
1974 240D turbo 617 swap, W201 5-speed project
Abomination Chevy Astro, 616 turbo swap, T5 5-speed, 4.56 diff. Work van
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post #13 of 20 (permalink) Old 11-30-2013, 04:41 PM Thread Starter
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so ive got most of the turbo mount setup, it got a little over welded here and there. I will be doing a ton of grinding to these parts to make em look presentable before painting them, but here are some current pics-

The turbo mount ended up looking like this, a two piece thingamabob-



First you install the lower S-pipe and support, putting it up through the long runner intake manifold (instead of over as my previous plans were)



Then you install this part on the valve cover and bolt them together, the bolt heads are an integral part of the lower piece. I set it up for easy access from above as the motivation-




here is the turbo resting in the approximate position. When I reclock the pipe, a 45 degree hose should have it meet the long runner intake

Also, it looks like its sitting on the fender, but there is a ton of room under there-



Here is how it looks from this angle. Im still undecided if I should do another extra bracket using the studs on the exhaust manifold like stock. I may do that later since thats common on all the turbo motors, and I might as well triangulate the support for the bigger turbo


1983 240D 4-speed, DD
1974 240D turbo 617 swap, W201 5-speed project
Abomination Chevy Astro, 616 turbo swap, T5 5-speed, 4.56 diff. Work van
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post #14 of 20 (permalink) Old 12-01-2013, 06:38 AM
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Quote:
Originally Posted by LWB250 View Post
Is that motor a turbo motor to begin with? If not you're looking at some serious engine issues if you try to turbocharge it…. like burned pistons, to begin with….
Depends on the amount of pressure he's putting in. 5-7 lbs of boost won't hurt an engine not designed with a turbo. After about 8, you're looking at higher probabilities of damage...
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post #15 of 20 (permalink) Old 12-01-2013, 06:47 AM Thread Starter
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Originally Posted by Grubeguy View Post
Depends on the amount of pressure he's putting in. 5-7 lbs of boost won't hurt an engine not designed with a turbo. After about 8, you're looking at higher probabilities of damage...
the plan is about 12-15 lbs of boost on this project.

1983 240D 4-speed, DD
1974 240D turbo 617 swap, W201 5-speed project
Abomination Chevy Astro, 616 turbo swap, T5 5-speed, 4.56 diff. Work van
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post #16 of 20 (permalink) Old 12-01-2013, 11:10 AM
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Very nice project you have going there. Keeping track of updates. Later.

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post #17 of 20 (permalink) Old 12-01-2013, 02:46 PM Thread Starter
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Bunch more pics-

S-pipe wrapped and painted-



how it looks installed with the long runner intake off-



Im still deciding how I want to do this second support like stock if I can. Obviously its gonna require a bracket, but im not sure how useful the support will be without a 3rd bolt of its own covering that kind of distance-



Meanwhile I had to remove the coupling to make room for the downpipe from this angle. There is an A/C line clearance issue to be worried about. I cannot absolutely say im not going to want A/C at one point, so id hate to remove this line-
better with the coupling removed though-




lots of room going down from this angle-



Im doing a 3 inch downpipe, direct from the turbo, clearance looks ok-



Another idea is to do a flex joint below a bracket and use the curve of the downpipe as a form of structural support in itself, or even off the bell housing-



similar to this type of bracket as an example-


1983 240D 4-speed, DD
1974 240D turbo 617 swap, W201 5-speed project
Abomination Chevy Astro, 616 turbo swap, T5 5-speed, 4.56 diff. Work van
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post #18 of 20 (permalink) Old 12-01-2013, 02:56 PM
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Now this looks neat! Love the welded bellhousing on that 5-speed. Gotta hand it to you for making use of the space you've got.

All you're missing now are some euro bumpers to complete the look!

'85 Euro 190E 2.3-16
'84 Euro 500SE ~100k miles
'51 Euro 170S *Being reborn*
'97 Jeep Wrangler Sport ~42k miles
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post #19 of 20 (permalink) Old 12-03-2013, 10:19 AM Thread Starter
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Originally Posted by VaiFanatic View Post
Now this looks neat! Love the welded bellhousing on that 5-speed. Gotta hand it to you for making use of the space you've got.

All you're missing now are some euro bumpers to complete the look!
thanks!

Not a fan of euro bumpers on the 115. Can't hit anything with them, prefer my US-spec bumpers, likely to keep the car alive longer

1983 240D 4-speed, DD
1974 240D turbo 617 swap, W201 5-speed project
Abomination Chevy Astro, 616 turbo swap, T5 5-speed, 4.56 diff. Work van
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post #20 of 20 (permalink) Old 12-03-2013, 10:20 AM Thread Starter
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ok, throwing out the S-pipe concept, decided to make a header instead. With the big exhaust I am planning, better off starting with excellent exhaust flow

1983 240D 4-speed, DD
1974 240D turbo 617 swap, W201 5-speed project
Abomination Chevy Astro, 616 turbo swap, T5 5-speed, 4.56 diff. Work van
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