240 Turbo
240 Turbo
here's The build http://www.superturbodiesel.com/std/old-...t-447.html
some turbo 240 history http://www.superturbodiesel.com/std/call...t-456.html
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
01-20-2010, 08:42 PM #1here are some pics of my 240d turbo 4spd with a rajay FB 40 turbocharger
here's The build http://www.superturbodiesel.com/std/old-...t-447.html
some turbo 240 history http://www.superturbodiesel.com/std/call...t-456.html
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
ForcedInduction
01-21-2010, 07:25 AM
#2
Its cool, but I still think you'll be much better off with a more modern turbo.
I think it should work quite well and you are maintaining a bit of nostaglia with this set up...
1982 300SD: 304,xxx Super M-pump with 7.5mm elements, 265 Nozzles, GT35 water cooled turbo, M90 Supercharger, A/W Intercooler, Serpentine drive belt, 3" SS exhaust with Magnaflow muffler, 240 breather, AEM dry Filter, Manual Boost Control, EGT / Boost / EMP gauges....Moved on to other projects
1995 F-350 7.3L PSD: 230,xxx 6.0 IC, DIY Stage 1 Injectors, 17* hpop, Tony Wildman Chip, John Wood Trans, 6.4L TC, 3" down pipe, 4" straight exhaust, 310 HP on wheel dyno - 8500# dually: 0-60 in 6.98
Suzuki Samurai: VW 1.9L TD, Trackick doubler transfer case (made by me) 5.8:1 transfer case gears, YJ springs front and rear with rear missing links, wheel base extended 14", diffs welded, some day a VNT.
Rudolf_Diesel
01-21-2010, 08:43 AM #3Nice job. I had a Corvair that I built an EFI system for and used the original Rajay that I made into a Hybrid using a larger Rajay compressor wheel and housing - I was able to get 20 lbs. of boost and 300 h.p.
I think it should work quite well and you are maintaining a bit of nostaglia with this set up...
1982 300SD: 304,xxx Super M-pump with 7.5mm elements, 265 Nozzles, GT35 water cooled turbo, M90 Supercharger, A/W Intercooler, Serpentine drive belt, 3" SS exhaust with Magnaflow muffler, 240 breather, AEM dry Filter, Manual Boost Control, EGT / Boost / EMP gauges....Moved on to other projects
1995 F-350 7.3L PSD: 230,xxx 6.0 IC, DIY Stage 1 Injectors, 17* hpop, Tony Wildman Chip, John Wood Trans, 6.4L TC, 3" down pipe, 4" straight exhaust, 310 HP on wheel dyno - 8500# dually: 0-60 in 6.98
Suzuki Samurai: VW 1.9L TD, Trackick doubler transfer case (made by me) 5.8:1 transfer case gears, YJ springs front and rear with rear missing links, wheel base extended 14", diffs welded, some day a VNT.
It works well but has big turbo lag I would like to put more fuel in it and an external waste gate and see if this help
My plan is to put this engine/turbo in a 1967 Mercedes 200d
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
01-21-2010, 01:04 PM #4I had a 1963 corviar turbo 4spd convertible never had enough money or time to work on it and sold it suck!
It works well but has big turbo lag I would like to put more fuel in it and an external waste gate and see if this help
My plan is to put this engine/turbo in a 1967 Mercedes 200d
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
diametricalbenz
04-08-2010, 10:49 AM #5Does that Rajay FB40 have any oil cooling at all? I noticed that Fengler's setup with the 220 motors didn't have any. How is the car running?
(04-08-2010, 10:49 AM)diametricalbenz Does that Rajay FB40 have any oil cooling at all?
Every turbo ever made is oil cooled.
ForcedInduction
04-08-2010, 05:35 PM
#6
(04-08-2010, 10:49 AM)diametricalbenz Does that Rajay FB40 have any oil cooling at all?
Every turbo ever made is oil cooled.
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-08-2010, 07:51 PM #7It runs great but lacks on power still it's better than stock but more fuel is needed the turbo has to have oil for lubrication /cooling of the bearing or it would be destroyed in seconds!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
(04-08-2010, 05:35 PM)ForcedInduction(04-08-2010, 10:49 AM)diametricalbenz Does that Rajay FB40 have any oil cooling at all?
Every turbo ever made is oil cooled.
I suppose the more pertinent question is where are the oil line connections? The Rajay's I have seen albeit very briefly in-situ seemed to hide them.
Currently Benzless but making do with a 96' Cummins 5.9 /P-Pump/HX-35
diametricalbenz
04-08-2010, 09:16 PM #8(04-08-2010, 05:35 PM)ForcedInduction(04-08-2010, 10:49 AM)diametricalbenz Does that Rajay FB40 have any oil cooling at all?
Every turbo ever made is oil cooled.
I suppose the more pertinent question is where are the oil line connections? The Rajay's I have seen albeit very briefly in-situ seemed to hide them.
Currently Benzless but making do with a 96' Cummins 5.9 /P-Pump/HX-35
(04-08-2010, 09:16 PM)diametricalbenz I suppose the more pertinent question is where are the oil line connections?
ForcedInduction
04-09-2010, 07:54 AM
#9
(04-08-2010, 09:16 PM)diametricalbenz I suppose the more pertinent question is where are the oil line connections?
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
05-03-2010, 10:11 PM #10Well the BBQ paint didn't hold up its all gone and the rust is back but the VHT flat black is still holding up well on my dads car!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
So I installed a new thermostat and upper radiator hose and it runs right on Temp no more over heating above 75mph and no more over cooling below 55mph! Also put some Redline diesel fuel catalyst in the tank and it runs great all of my warm idle nailing is gone and it idle smooth as a baby's butt!
At times it use to sound like a hammer tapping on the block it would nail so bad!
And on my last tank I got 29.2mpg! about 3 mpg better than ever! at least since since the turbo install! and all of the work
I did was on 6 mo old 1/2 empty tank with mixed driving!
Now I found a tiny diesel leak at the copper washer on top of the fuel filter and one leaking injector cross over hose that's next on the list! Along with installing my oil temp gauge and sensor!
And I'm in desperate need of a taller ratio rear diff/speedo or 5spd!!! so I can cruise 75mph with out being at dam near redline/8psi boost! That really kills my millage on a full tank doing 75mph all week to work my mileage drops off to about 24-25mpg and at 55-65mph I was getting just 27-28mpg! and touching boost with light throttle around 2psi at 65mph!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
09-27-2010, 08:08 PM #11Sorry for the long break it's been about 6 months since I've driven this car!
So I installed a new thermostat and upper radiator hose and it runs right on Temp no more over heating above 75mph and no more over cooling below 55mph! Also put some Redline diesel fuel catalyst in the tank and it runs great all of my warm idle nailing is gone and it idle smooth as a baby's butt!
At times it use to sound like a hammer tapping on the block it would nail so bad!
And on my last tank I got 29.2mpg! about 3 mpg better than ever! at least since since the turbo install! and all of the work
I did was on 6 mo old 1/2 empty tank with mixed driving!
Now I found a tiny diesel leak at the copper washer on top of the fuel filter and one leaking injector cross over hose that's next on the list! Along with installing my oil temp gauge and sensor!
And I'm in desperate need of a taller ratio rear diff/speedo or 5spd!!! so I can cruise 75mph with out being at dam near redline/8psi boost! That really kills my millage on a full tank doing 75mph all week to work my mileage drops off to about 24-25mpg and at 55-65mph I was getting just 27-28mpg! and touching boost with light throttle around 2psi at 65mph!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
I had a spare trans laying around in my shop that someone had donated to me for my other car! 2hr later we had it running like a champ then I got the turbo kit and got it installed
My dad got another 300d with a bad engine I traded him my really good 617 turbo out of my 1980 300sd I still think he got the beater deal!
I call it my test mule once I get it running just right its engine is going into my other 240d with the manual sun roof and power windows 16" wheels and vented brakes and the list goes on
I also have a brand new clutch kit for it and a really good 32k transmission for it
Now I'm just waiting for some vacation time!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
09-27-2010, 11:19 PM #12The history I got the 240d for $500 delivered from Nebraska for my dad with a recently rebuilt engine and they told me it had a bad clutch which ended up working fine! As it turned out it got put in two gears at speed due to worn shifter bushings the end result 1st,reverse got pushed out the side of the trans case I then drove it with out fluid! to my shop 30 miles away with only a noisy 2,3,4 gears!
I had a spare trans laying around in my shop that someone had donated to me for my other car! 2hr later we had it running like a champ then I got the turbo kit and got it installed
My dad got another 300d with a bad engine I traded him my really good 617 turbo out of my 1980 300sd I still think he got the beater deal!
I call it my test mule once I get it running just right its engine is going into my other 240d with the manual sun roof and power windows 16" wheels and vented brakes and the list goes on
I also have a brand new clutch kit for it and a really good 32k transmission for it
Now I'm just waiting for some vacation time!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
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Medieval Norman Warriors Sculptures Odo
dorthywaggane
12-01-2010, 11:54 PM #13The post is cool but maybe you should discuss the modern turbo.
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Medieval Norman Warriors Sculptures Odo
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
12-02-2010, 12:15 AM #14I want to mod the turbo 5 cylinder manifold to fit the 4 cylinder and use a stock k26 turbo off a 300d
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
ForcedInduction
12-03-2010, 07:47 AM
#15
The K26 isn't very efficient. Maybe a T3 from a Rabbit/Golf since its got the smaller .36 turbine?
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
12-03-2010, 10:53 AM #16Any thing would be an improvement!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
I take some pics later but the reason behind all of this work it move my very nice running turbo motor from the car it in currently witch is striped out rust bucket!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
05-29-2011, 03:05 PM #17Well I am swapping this engine & manual transmission In to my 1980 green 240d witch is currently an auto but it has a manual sunroof and power windows and euro lights with my hella fog lights like in my pic
I take some pics later but the reason behind all of this work it move my very nice running turbo motor from the car it in currently witch is striped out rust bucket!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
(05-29-2011, 03:05 PM)willbhere4u ...
I take some pics later but the reason behind all of this work it move my very nice running turbo motor from the car it in currently witch is striped out rust bucket!
Aw come on, nothing but some duct tape covered with bondo would fix.
.
Gota love Mercedes Diesels!
.
DeliveryValve
05-29-2011, 05:21 PM #18(05-29-2011, 03:05 PM)willbhere4u ...
I take some pics later but the reason behind all of this work it move my very nice running turbo motor from the car it in currently witch is striped out rust bucket!
Aw come on, nothing but some duct tape covered with bondo would fix.
.
Gota love Mercedes Diesels!
.
Then I pulled the transmission & engine out of the blue 240 turbo 4spd car
Then I noticed the lower LH rad support was rusted out so I cut out some patch panels out of my blue car and welded them in i realized I had to pull the LH fender off witch was made of bondo and rust with a lite coat of paint to make it look nice on my green car
luckily my blue car had a nice replacement fender the only nice part of the car! and because it had already been replaced it was not glued on! hell yea!
If you didn't know from the factory they are glued on the top edge and almost impossibly to remove with out destroying them! it took my 2 hours to get the off my green car and 15min to pull the one off the blue car!
next week I need to patch the lower rocker and bolt up my fender and put the turbo engine in!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
07-24-2011, 09:14 PM #19finally some real progress i got the engine and trans out of the green auto car
Then I pulled the transmission & engine out of the blue 240 turbo 4spd car
Then I noticed the lower LH rad support was rusted out so I cut out some patch panels out of my blue car and welded them in i realized I had to pull the LH fender off witch was made of bondo and rust with a lite coat of paint to make it look nice on my green car
luckily my blue car had a nice replacement fender the only nice part of the car! and because it had already been replaced it was not glued on! hell yea!
If you didn't know from the factory they are glued on the top edge and almost impossibly to remove with out destroying them! it took my 2 hours to get the off my green car and 15min to pull the one off the blue car!
next week I need to patch the lower rocker and bolt up my fender and put the turbo engine in!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
I've decided to order 2 new Guibo couplers for the drive shaft and new oil cooler lines and a new high pressure power searing line.
I already have a new drive shaft center support bearing, trans mount,engine mounts and engine shock
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
10-17-2011, 05:27 PM #20More progress I got the 4spd transmission installed with a new transmission mount
I've decided to order 2 new Guibo couplers for the drive shaft and new oil cooler lines and a new high pressure power searing line.
I already have a new drive shaft center support bearing, trans mount,engine mounts and engine shock
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
One question? Do the three bold flanges on each end of the drive shaft have to line up? they where not before it took it apart I know because I marked it
Thanks Will
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
03-17-2012, 06:03 PM #21Today I installed and hooked up the 4spd shifter and rods and got the center support bearing back on the drive shaft
One question? Do the three bold flanges on each end of the drive shaft have to line up? they where not before it took it apart I know because I marked it
Thanks Will
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
(03-17-2012, 06:03 PM)willbhere4u Today I installed and hooked up the 4spd shifter and rods and got the center support bearing back on the drive shaft
One question? Do the three bold flanges on each end of the drive shaft have to line up? they where not before it took it apart I know because I marked it
Thanks Will
I never had a problem just bolting the drive shaft in any which way it was when I got it up there. doesn't have to match the flanges in the same way it was, as long as the front and rear sections of the shaft itself are still clocked the way they were together.
This is some great progress!
1974 240D 617 turbo swap, W201 5-speed, in the works project
1983 240D 616 stock, DD
1989 Chevy Astro, 617 turbo swap, T5 5-speed, 4.56 diff, work van
(03-17-2012, 06:03 PM)willbhere4u Today I installed and hooked up the 4spd shifter and rods and got the center support bearing back on the drive shaft
One question? Do the three bold flanges on each end of the drive shaft have to line up? they where not before it took it apart I know because I marked it
Thanks Will
I never had a problem just bolting the drive shaft in any which way it was when I got it up there. doesn't have to match the flanges in the same way it was, as long as the front and rear sections of the shaft itself are still clocked the way they were together.
This is some great progress!
1974 240D 617 turbo swap, W201 5-speed, in the works project
1983 240D 616 stock, DD
1989 Chevy Astro, 617 turbo swap, T5 5-speed, 4.56 diff, work van
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
03-20-2012, 09:30 AM #23I have a rear diff out of a 1983 300d 3.07 ratio with newish axles and a matching speedometer head hopefully going in next weekend weather dependent
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
To-date I've swapped in the turbo 240d engine new 4spd transmission instead of the auto and new 300d 3.07 rear diff and rebuilt the 240 4spd drive shaft hooked up the shifter and added a pedal set in the past on this car I rebuilt the entire suspension and added Bilstein HD shocks and vented rotors and SS brake lines!
Last I really want to find a new 300d oil cooler and radiator and fan clutch but Surfrodder's method is also very tempting
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-01-2012, 11:14 AM #24I finally got the new 3.07 diff and rebuild drive shaft installed!
To-date I've swapped in the turbo 240d engine new 4spd transmission instead of the auto and new 300d 3.07 rear diff and rebuilt the 240 4spd drive shaft hooked up the shifter and added a pedal set in the past on this car I rebuilt the entire suspension and added Bilstein HD shocks and vented rotors and SS brake lines!
Last I really want to find a new 300d oil cooler and radiator and fan clutch but Surfrodder's method is also very tempting
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-02-2012, 11:40 AM #25I just put a tach/clock in my speedometer cluster with the matching speedometer for the 3.07 diff
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-08-2012, 07:32 PM #26I finished hooking everything up this weekend I bled the clutch and breaks and drove it around for a bit now I just need to weld up the rust and replace the RH fender and and reinstall my boost and EGT gauge's
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-09-2012, 09:12 AM #27I also picked up a 1985 w123 300d California model air filter assembly the one that goes in the RH fender any idea what holds it in there i found the air cleaner box and the hose and bottom bracket that it sits in but no mounting hardware? like this one in the pic I think it will work with my 240d turbo nicely!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
Mb 1984 w201 om603 swap.
Mb 1986 w201 190E 2.3-16v
Mb 2004 w203 C230k
George3soccer
04-09-2012, 09:54 AM #28check out forced post in the air filter post in the engine section. There is a picture of the mounting bracket.
Mb 1984 w201 om603 swap.
Mb 1986 w201 190E 2.3-16v
Mb 2004 w203 C230k
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-09-2012, 11:42 AM #29Yea that's the bracket I have and the air filter sits in that bracket but there must be something that holds the whole assembly down so it wont bounce out?
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
Graminal95
04-10-2012, 05:18 PM #30There are two brackets that bolt to the radiator support and the expansion tank for the coolant. Each arm has a little rubber grommet on the end that holds the air cleaner housing in place.
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-10-2012, 06:59 PM #31sweet thanks!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
what size gauges did you use to get 3 of them to fit where the ash tray was? looks like some wood you drilled appropriate size holes into? did you build it into the track or slide out of the old ash tray? looks like you tilted them to face the driver? that looks pretty sweet
I had to cut the inside of the console where the ash tray mounted to make it fit with all of the gauges they where all 52mm VDO gauges
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
05-16-2013, 09:42 PM #33That gauge pod was out of a Volkswagen or at least it had a Volkswagen part number on it. It fit pretty well in there but
I had to cut the inside of the console where the ash tray mounted to make it fit with all of the gauges they where all 52mm VDO gauges
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
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