I have a 1990 Mercury Cougar that I am planning an OM617 conversion on.I am using a 240D fly wheel and pressure plate along with the bell housing from a 4 speed 240D.The transmission will be either a Cougar/T-Bird M5R2 or a T56 from a Camaro/Firebird.I will choose the pressure plate for the appropriate tranny.Transmission is dictated by the odd shifter location in the MN12 chassis.The guys on the Benz forums build T5/6 to replace autos.Some use the 240D bell housing,flywheel,and pressure plate so I'm gonna give it a try.Anyone wondering about this swap,it has major hurdles.The K member has to be notched for the Benz oil pan and the oil pan has to be notched for the engine to set far enough back to keep the F/R weight ratio in check.The factory 3.8 sits way back and has one hell of a fan shroud.I'm gonna add some extra oil capacity by enlarging the pan.Remember the OM617 use oil cooling because of the oil squirters.That's my plan.Open to ideas and suggestions.

Now for the issues and the questions.My factory 3.8L has a serpentine belt set up and the OM617 uses V belts.I don't wanna keep the Ford A/C compressor or the Ford power steering pump.The Ford compressor and power steering pump are common and have been used in V belt set up.So I know I can convert them to run V belts.I have issues with the Benz P/S pump and A/C.I know that the lines are gonna have to be made either way I go.Which leads me to the following questions.

1)Can the Benz P/S pump power my steering rack and my brake hydro booster?
2)If so,where do I purchase the hydraulic fittings for the Benz P/S pump?
3)Can the Benz A/C compressor handle and operate correctly with R134A refrigerant?
4)Where could I purchase fittings for the Benz A/C compressor?
5)Is there another Benz P/S pump and A/C compressor that will bolt up and work better?
6)Can the Benz P/S pump be flowed to work with my brake hydro booster?
7)Any other ideas or suggestions?

I also plan to post this over on the Benz forum,when my membership is approved.What takes so long over there?Maybe time zone difference or I'm just an impatient @$$?

I'd rather stick with the Benz units as they are already in place,and hoses are much easier to fabricate than brackets.

Here are my resources for info besides here.

TCCoA Forums - Powered by vBulletin
Super Coupe Club of America Forums - Powered by vBulletin
SuperTurboDiesel.com- Performance Mercedes turbo diesels
Cummins 4BT & Diesel Conversions Forums

Sorry the pics are so crappy.

Here's a shot of that huge fan shroud.Also notice where the A/C compressor is.It's to the side and behind the air box.Plan to keep the air box.Also note how far back the engine sits.This car handled good for it's day.



Power Steering Unit.I know this unit can be flowed for my brake hydro booster.I just don't wanna have to fab brackets and locate V belt pulleys.

 

I got some good info over on the Mercedes board if anyone is interested. OM617 Conversion with Questions/Bare with me plz.

This isn't my first engine swap.I've done a few,but this is my first ever diesel conversion.Trying to get my ducks in a row so the swim across the lake is easier.

 

As for the Benz p/s pump, it may be easyer to use the ford pump and make new mounts as the Benz pump mounts high and far to the side. I couldn't use it and went with a remote rez unit. I also would think it would be easyer to use the ford a/c pump, change the pully and make new mounts. The Benz GM a/c comp is huge and not as efficent as the ford unit. The OM617 has a built in vacuum pump, so you can retain the stock vac brake booster. I know you said you don't want to fab new brackets, but I had no choice due to the fact that the stock Benz stuff wouldn't fit. You may just have to test fit first to see what needs changed. Hope that helps!

 

Thanks.I am weighing my options carefully.I think the fit in the car will be the final determining factor.I just wanna make sure I have my options lined up,so I'm not standing around staring and scratching my *** Like a dumby.

I'm ditching the weak vacuum brake assist.It all out sux on a 3900lbs car,and I am going with 4 wheel disc brakes from a 93+ Super Coupe and hydro boost.I will retain the Benz vacuum booster for the heat and A/C.

 

Does anyone know of an install between a Chevy Duramax in a 49-52
Chevy or any diesel for that matter?

Is there a place I can find out the dimisions for various engines? and
then compare it to my '51 engine compartment before I even think about
putting one in the wagon.
thank you
gene

 

Try a google search for engine dimensions and engine weights.Try this. http://fixrambler.com/engineweightchart.txt Note that Some Duramax engines are the same as Detroit engines.

 

interesting conversion the t5 will work I am in the final stages of making my adapter plate I used the 240d flywheel pressure plate and bell housing and a s10 14 tooth spline clutch 8.5" had to change the input shaft but that with bearings and seals was about 50.00 you will have to use a internal slave clutch tb and as far as belts I would look at a universal ac pump so it is 134a compliant and ps use either ford or gm and alt the gm has always been a favorite it has a internal regulator and simple to make work if yo need i can send you pictures of my adapter plate should have it together next week

 

T-5 won't work in my application.The shifter has to set back passed the tail shaft and the T-5 is too short to get back that far.The Cougar/T-bird came with a specific M5R2 and T56 are the only transmissions I can find that can get the shifter back far enough so it's not under the dash.I may have to scrap this plan as there are people in my area that are buying up om617,om603,and om606 diesels.Three yards in my area have told me that someone is calling around trying to get as many as possible.I dunno what the future holds.Maybe I can buy one from someone locally,but it'll cost.

 

It's really a interesting conversion.I am very impressed.Thanks for sharing with us.

 

well that bites keep looking for a parts car try searchtempest.com just search 300d or 300sd I know where there is a great running one car was in a fire but the guy thinks it is worth more that it is worth