Mercedes Turbo-Diesel to W56--'89 4Runner Build - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 01-06-2008, 05:03 PM   #1 (permalink)
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Mercedes Turbo-Diesel to W56- UPDATE PG -8

I'm not sure if you folks will be interested in this engine swap/build. So, I'll leave it up to you. We have NO rock-crawling near my Maryland home, and almost no offroad trails in the area. This truck is going to become my daily driver/ work truck/ farm truck.

The truck is ready for paint. I spared you guys the chassis/body mods since it's pretty mundane compared to the crazy shit you folks build. I wanted a old 4-door Hi-Lux, but since the U.S. never got that, I made a four-seater with a short bed.

Sorry for the crappy first pic.

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Old 01-06-2008, 05:07 PM   #2 (permalink)
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more pics please
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Old 01-06-2008, 05:23 PM   #3 (permalink)
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Looks good is there an adapter avalible for that engine/trans combo?
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Old 01-06-2008, 05:31 PM   #4 (permalink)
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(begin shameless suck-up) The reason I wanted to post this thread HERE, is because of the tremendous fabrication and machinist skills I've seen on Pirate. I hope you folks can see past my non-rockcrawler limitations. (end suck-up)

On to the swap.......

Mating the W56 to the Benz engine looks like it's going to be a little involved. (This is my first engine swap by the way) I know this can be done because I have some limited photos from a guy who did it. He was a machinist, and he couldn't remember all the details of what parts he used, and the photos show little detail. These were second-hand pics and info. I found the thread on ToyotaDieselMadness.com of someone who planned to replicate the swap, but later, he decided to keep the Benz auto-trans and leave the truck 2WD.
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Old 01-06-2008, 05:32 PM   #5 (permalink)
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Looks good is there an adapter avalible for that engine/trans combo?
No, I need to fab it.

I am wide-open to input on any of this.

Roy
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Old 01-06-2008, 05:46 PM   #6 (permalink)
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Removed the transmission today, and mainly sat and familiarized myself with the engine layout, plumbing, etc.

This is an all-mechanical diesel. No electronics of any kind. This engine in stock form, is rated at 125HP and 175 lbs of torque. I've been reading up on the Benz forums, and with a few simple mods, can produce about 170HP and 240 lbs. of torque. Intercooling this engine is pretty straight forward as well.

The "OM" series engines are known as the most dependable engines Mercedes has ever produced; many going 400,000+ miles before needing a rebuild.
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Old 01-06-2008, 08:01 PM   #7 (permalink)
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Please keep us posted with pictures!
I have looked at the merc diesels for a swap MANY times, but I don't have the equipment to adapt the transmission. I can't wait to see what you come up with.
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Old 01-06-2008, 08:38 PM   #8 (permalink)
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I was looking into this conversion some years ago, company in Cali was working on the conversion, but never completed it. Great little motor, +2 on lots of picts!
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Old 01-06-2008, 08:59 PM   #9 (permalink)
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Ooh, I'll be watching. I've often thought this would be a great swap. I think it was 4x4labs that was working on a kit.

ETA: I'd be very interested to see the pics you have of a successful swap.

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Old 01-06-2008, 09:08 PM   #10 (permalink)
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Ever thought of dumping your benz diesel for an audi one? Audi Diesels had an asian warner auto trans behind them, which is the same auto trans that came in 22re/auto toyota trucks. This means you can use an inchworm adapter to a gear drive transfer case. They motor can be easily found in late 80's Volvo sedans.
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Old 01-07-2008, 04:35 PM   #11 (permalink)
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Here is the thread that has the pics of the first install with the five-speed.

I don't want to link to all the pics because it might be a Pirate bandwidth issue.

Roy

http://toyotadiesel.com/forums/showt...light=mercedes
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Old 01-07-2008, 04:37 PM   #12 (permalink)
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Ever thought of dumping your benz diesel for an audi one? Audi Diesels had an asian warner auto trans behind them, which is the same auto trans that came in 22re/auto toyota trucks. This means you can use an inchworm adapter to a gear drive transfer case. They motor can be easily found in late 80's Volvo sedans.

Well, since I already have this, I'm going to use it. I looked at Volvo and Isuzu diesels as well as turbocharging a 240D Benz. This is just what I found nearby at a reasonable price.

Roy
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Old 01-07-2008, 04:41 PM   #13 (permalink)
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Ooh, I'll be watching. I've often thought this would be a great swap. I think it was 4x4labs that was working on a kit.

ETA: I'd be very interested to see the pics you have of a successful swap.
Please Please Please dont give up! I wanna see this happen. 4x4labs was (is?) working on a kit that I've been drooling over for some time. Their website has been all jacked for a long time so its hard to find the info. I've called them a few times and was put on their list of people to get ahold of when its done but that was a loooong time ago. But you might try to give them call.
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Old 01-07-2008, 05:33 PM   #14 (permalink)
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sounds like a interesting project, I will be keeping an eye on the build. I too want to see how you adapt the motor to tranny.
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[QUOTE=steveh;7244017]Keep it on track guys.
DRM and I will be watching. We need our TG paychecks ...... [/QUOTE]
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Old 01-07-2008, 06:32 PM   #15 (permalink)
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Very few 300TD's came to the U.S. with manual transmissions. I believe they use a 33lb flywheel. The 240D uses a 23lb flywheel.

Both are a bolt-on swap.
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Old 01-07-2008, 08:14 PM   #16 (permalink)
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why not use a 300td manual flywheel with the 240d tranny? cuz u cant get a hold of one?

I wanted to do this. it will be interesting to find out your results. good luck!
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Old 01-07-2008, 09:31 PM   #17 (permalink)
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I'm watching this one also.. If only the transmission issue was easier.. :-)

My first car was a 220d. Even weaker than the 240D.
I heard it made it over 300k, eventually dropped the timing chain.
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Old 01-07-2008, 11:02 PM   #18 (permalink)
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mmm, inline 5 cylinder diesel - i drove a '79 300sd turbo diesel for a few years - never gave me a single problem. engine's definitely better suited to a truck than a sedan, it was slow as molasses.
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Old 01-08-2008, 03:01 AM   #19 (permalink)
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Have you tried putting the engine in the engine bay? I tried it with mine and had to go a different route....that is a long sucka!

and just so you know - Rausch Creek probably is less than 2 hours for you for wheeling and has some fantastic wheeling...

bk
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Old 01-08-2008, 09:59 AM   #20 (permalink)
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I had exchanged e-mails with 4x4Labs about their conversion project a few years ago. IIRC, the fact that the engine and transmission were balanced together was the issue that was stopping them. Will be interested to see how this progresses.
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Old 01-08-2008, 05:29 PM   #21 (permalink)
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why not use a 300td manual flywheel with the 240d tranny? cuz u cant get a hold of one?

I wanted to do this. it will be interesting to find out your results. good luck!

Finding a 300TD manual flywheel will be tough. It's my understanding that very few manual 300TD's came to the U.S. This path gives the option of using a Toyota transfer case doubler. I'm also hoping for better mileage with the five speed. If I used the Benz trans, I would still need a divorced transfer case set-up since the Toyota trans and transfer case are integral.
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Old 01-08-2008, 05:33 PM   #22 (permalink)
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Have you tried putting the engine in the engine bay? I tried it with mine and had to go a different route....that is a long sucka!

and just so you know - Rausch Creek probably is less than 2 hours for you for wheeling and has some fantastic wheeling...

bk
Thanks for the heads-up on the wheeling. I need to research that!

I have had the engine in the bay, and I think I have the length issue solved as well.

We'll see.
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Old 01-08-2008, 05:46 PM   #23 (permalink)
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I had exchanged e-mails with 4x4Labs about their conversion project a few years ago. IIRC, the fact that the engine and transmission were balanced together was the issue that was stopping them. Will be interested to see how this progresses.
I have read about this "balance issue" quite a bit while researching this swap. I am going to find out once and for all if this is true. I have a feeling that it's not true. It makes no sense to me to not balance the engine, and instead balance the two units as one. Honestly, I don't even see how that's possible with no access to the flywheel/flex-plate while the units are joined.

Tonight, I pulled the flex-plate and the Benz transmission "transition" plate that goes between the trans and engine block. I threw those in the trunk along with the Toyota manual flywheel. I'm now waiting on delivery of the 240D manual-flywheel I got on eBay. Progress will slow until that arrives.

While I'm waiting, I think I'm probably going to organize the garage and strip the engine down to the long block, clean and paint everything. A wire was between the valve cover and head, and everything is pretty damn filthy.

I'll post updates as they occur.

Roy
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Old 01-09-2008, 10:42 AM   #24 (permalink)
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Question on the bodywork - did you extend the cab of a pickup into the bed or is that a 4-Runner you are starting with? The Merc engine is cool as well, but I always like a purpose built rig whatever the configuration.
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Old 01-09-2008, 05:17 PM   #25 (permalink)
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Question on the bodywork - did you extend the cab of a pickup into the bed or is that a 4-Runner you are starting with? The Merc engine is cool as well, but I always like a purpose built rig whatever the configuration.
I started with an '89 4Runner. I lengthened the cab.

Roy
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