Alright, I've spoken of this in the past. I am going to try to start tomorrow. Any last minute tips, tools I need to purchase while stores are open today (outside of any normal tools). I've done many 3.5L to 3.0L re-powers, but only between W126's, never a W140 as the destination.

Here's what I am hearing:

Swap oil pan
Fabricate(?) a pickup tube that's a combination of a W140 and a W126 pickup tube (Not sure why)
AC Compressor bracketry needs to be swapped (same as W126)
Exhaust Manifold and Turbo swapped.
Oil filter housing cap (with center-bolted top), hopefully the whole housing doesn't need to be swapped over.
Motor Mounts are different

Questions still up in the air:

Can I leave windage tray out of this equation? Would rather not bother with it.

Can I use the W126 oil pump?

ANYTHING else I should swap over that I am missing?

__________________
1987 300SDL #1, 1987 300SDL #2, 1980 240D, 1982 300SD, 1994 S350, 1990 350SDL, 1991 350SD, 1985 300D, 2005 E320CDI

Gone, but not forgotten: 1981 300SD, 1982 300SD, 1987 300SDL, 1983 300TD, 1980 300CD, 1981 300SD #2, 1987 300D, 1987 300TDT, 1980 300D

I'd leave the windage tray in, but weld the nuts in place (or at least put some threadlocker on them). IIRC part of the tray is attached to the block and part to the oil pan?

The 3.5 has different temp sensors / switches, but those should be easy to move over to the 3.0.

-J

__________________
1991 350SDL. 230,000 miles (new motor @ 150,000). Blown head gasket

Tesla Model 3. 205,000 miles. Been to 48 states!
Past: A fleet of VW TDIs.... including a V10,a Dieselgate Passat, and 2 ECOdiesels.
2014 Cadillac ELR
2013 Fiat 500E.

Tweak the pump!

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

That's easy enough to do with the motor in the car I'd get it running correctly stock first.

-J

__________________
1991 350SDL. 230,000 miles (new motor @ 150,000). Blown head gasket

Tesla Model 3. 205,000 miles. Been to 48 states!
Past: A fleet of VW TDIs.... including a V10,a Dieselgate Passat, and 2 ECOdiesels.
2014 Cadillac ELR
2013 Fiat 500E.

Keep the pump and oil pan together to be sure of proper placement. If you ditch the windage tray but keep the .971 pump, make up for the thickness between the main bearing cap and the oil pickup stand so you don't stress the oil pump casing. This is a view of a .96 pickup in a .96 pan. You might be able to look into the .971 oil pan through the oil level sender hole so see if there's a comparable gap between the bottom of the .96 pickup and the floor of the pan.



Before you decide to keep the .96 oil filter housing, make sure the W140 oil cooler lines will bolt up.

Are you swapping heads or does the .96 already have a later casting? Definitely get the .971 gauge sender cum glow relay temp sensor in place while the engine's out. It'll be difficult enough without removing the intake manifold.

Which IP are you running?

Sixto
87 300D

It's either a 17 or 22 head. It's not readily available now. I'm running the 3.0L pump. It's been cranked up for more fuel by the PO's comments. I wasn't aware the oil cooler lines may not work. I need to verify that for sure before bolting it in.

__________________
1987 300SDL #1, 1987 300SDL #2, 1980 240D, 1982 300SD, 1994 S350, 1990 350SDL, 1991 350SD, 1985 300D, 2005 E320CDI

Gone, but not forgotten: 1981 300SD, 1982 300SD, 1987 300SDL, 1983 300TD, 1980 300CD, 1981 300SD #2, 1987 300D, 1987 300TDT, 1980 300D

Wait a minute Sixto, that looks like a 3.0L pan with the side sump. If I swap pans, isn't one pan a front sump and the other a rear sump? How difficult is it going to be to swap the 3.5L pump into the 3.0L engine? Will I need an oil pump gasket (that I do not have)?

__________________
1987 300SDL #1, 1987 300SDL #2, 1980 240D, 1982 300SD, 1994 S350, 1990 350SDL, 1991 350SD, 1985 300D, 2005 E320CDI

Gone, but not forgotten: 1981 300SD, 1982 300SD, 1987 300SDL, 1983 300TD, 1980 300CD, 1981 300SD #2, 1987 300D, 1987 300TDT, 1980 300D

.96, .970 and .971 are all front sump. Only the .96 has a side compartment. The .96 pan definitely won't drop into a W140 K-member. I don't see a gasket or o-rings in the EPC. Strange.

Put a straight edge across the gasket surface of each oil pan and measure the distance to the floor. If the .971 pan is only slightly deeper, keep the .96 oil pump as is.

IIRC .96 main cap bolts aren't threaded to accept windage tray fasteners.

Sixto
87 300D

Or, maybe this is the better way to phrase a question so I'm clear on something.

What would the steps be to keep the 3.0L oil pump in the 3.0L engine installed into a W140? Would I have to move the pickup tube, and windage tray over to the 3.0L?

__________________
1987 300SDL #1, 1987 300SDL #2, 1980 240D, 1982 300SD, 1994 S350, 1990 350SDL, 1991 350SD, 1985 300D, 2005 E320CDI

Gone, but not forgotten: 1981 300SD, 1982 300SD, 1987 300SDL, 1983 300TD, 1980 300CD, 1981 300SD #2, 1987 300D, 1987 300TDT, 1980 300D

Hmmm. You know, I have a 3.5L out of a last generation W126 without a side sump. Am I just bringing in unnecessary confusion to this already convoluted swap, or would it offer some value as it may more closely match the depth of the 3.0L pan?

__________________
1987 300SDL #1, 1987 300SDL #2, 1980 240D, 1982 300SD, 1994 S350, 1990 350SDL, 1991 350SD, 1985 300D, 2005 E320CDI

Gone, but not forgotten: 1981 300SD, 1982 300SD, 1987 300SDL, 1983 300TD, 1980 300CD, 1981 300SD #2, 1987 300D, 1987 300TDT, 1980 300D

The .970 pan is -16 02, the .971 pan is -17 02. Functionally different? I don't know. The .971 pan definitely fits the W140. Is the oil pickup location different? Measure and find out! I wouldn't try a shallower pan but a slightly deeper pan shouldn't be a problem.

Speaking of which, keep the appropriate dipstick for the pan. That might mean using the side dipstick tube that came with the .971. How wonderful would it be to dedicate the front dipstick tube to your Topsider?

Sixto
87 300D

And so it begins...

Attached Thumbnails

 

__________________
1987 300SDL #1, 1987 300SDL #2, 1980 240D, 1982 300SD, 1994 S350, 1990 350SDL, 1991 350SD, 1985 300D, 2005 E320CDI

Gone, but not forgotten: 1981 300SD, 1982 300SD, 1987 300SDL, 1983 300TD, 1980 300CD, 1981 300SD #2, 1987 300D, 1987 300TDT, 1980 300D

Jeez. 5 hours just to remove the engine out of the W140. Lots of changes from the W126. Throttle cabling, ridiculous tube cladding on alternator harness, and that tube going over the top of the bellhousing, crazy. I couldn't even see the bolt at the top, never seen an area that tight to the firewall. I had to raise the engine, remove the mounts, and then drop the engine on the cradle to gain a few inches of access. Never thought it would have taken that long. Eh well, next weekend, hopefully I can get everything swapped over between engines.

Sixto, thanks for all the advice.

__________________
1987 300SDL #1, 1987 300SDL #2, 1980 240D, 1982 300SD, 1994 S350, 1990 350SDL, 1991 350SD, 1985 300D, 2005 E320CDI

Gone, but not forgotten: 1981 300SD, 1982 300SD, 1987 300SDL, 1983 300TD, 1980 300CD, 1981 300SD #2, 1987 300D, 1987 300TDT, 1980 300D

You didnt pull the trans with it?

You should try the top bolts on the 603.

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

?? Isn't this is a 603(.971) coming out?

Sixto
87 300D