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Turbo 616 powered Astro Van build
JB3 Offline
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#1
Turbo 616 powered Astro Van build
This is continued from another thread. And For the record, this van is for WORK, not for "pedo" activities! Rolleyes Big Grin Those of you who can only think in that direction know who you are. Big Grin

Picked up this van for cheap, and after creating cash selling another car, decided to use the 4x4labs OM617 adapter to mate the 616 to a NV3500 GM 5-speed I have as an alternative to making my own plate, spacers, and other custom stuff.

Here are some pics, got the adapter kit in the mail already, very nice unit.

here are the contents, whole kit includes machined plate, bolt kit, pilot bearing adapter, and mercedes/chevy flywheel. The flywheel is a much larger diameter than the OEM mercedes, and has a replaceable friction surface. I estimate its only slightly lighter than the OEM flywheel. I will try and weigh them later.

I will have to provide all chevy clutch stuff, and this setup is designed to use a ford V-10 starter instead of the MB starter. Its a little smaller, but will have the added benefit of the better gear ratio for starting. Its also pretty cheap.

The kit-

.jpg   4x4labskit.jpg (Size: 63.98 KB / Downloads: 7,330)

pilot bearing adapter, fits into the end of the MB crank and allows a smaller GM pilot bearing spaced further out. I have a MB pilot bearing in the pic for comparison-

.jpg   pilotbearingadapter.jpg (Size: 58.62 KB / Downloads: 6,219)

heres how the plate looks on the trans, have not pulled the 616 yet, more pics later of it all together-

.jpg   nv3500plate3.jpg (Size: 75.35 KB / Downloads: 6,104)

.jpg   nv3500plate2.jpg (Size: 65.52 KB / Downloads: 6,361)

heres a tranny comparison- MB Iron 4-speed closest, MB aluminum 5-speed, and the NV3500 5-speed.

.jpg   trannycompare1.jpg (Size: 71.98 KB / Downloads: 7,572)

heres the van (needs a little body work and a tire Big Grin) Runs and drives, stock with Rwd and a V6 auto configuration- I was saying in the other thread, but ill cover it here again, the fully loaded generation 2 astro is actually only 600 lbs heavier than the 123 mercedes. This is a smaller, lighter generation 1 cargo version of the astro. With that in mind, I am thinking that this van might be very close to the 2 ton mark. I will take it by the scales before i rip out the motor so we have some real numbers.


.jpg   astro2.jpg (Size: 81.67 KB / Downloads: 6,371)
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

(This post was last modified: 11-07-2010, 02:05 PM by JB3.)
11-07-2010, 01:57 PM
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300D50 Offline
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#2
RE: Turbo 616 powered Astro Van build
I see the cast iron tranny! Wooo!

Showoff, getting shiney bling bling adapter plates... :p I'll show you... Big Grin

And those astro's SCREAM pedo, it's what the media puts in peoples heads daily...
Ifins ya need help, be sure to let me know. And I've got a spare 616 you can have for the right price as well...
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
11-07-2010, 02:45 PM
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mike-81-240d Offline
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#3
RE: Turbo 616 powered Astro Van build
Can I borrow your custom 5 speed?.... Tongue
1981 Mercedes 300TD Lowered 4 speed manual Holset HX30 
11-07-2010, 02:49 PM
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JB3 Offline
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#4
RE: Turbo 616 powered Astro Van build
(11-07-2010, 02:49 PM)mike-81-240d Wrote: Can I borrow your custom 5 speed?.... Tongue

you can borrow the jig if you want, just let me know. Mine is destined for my 300D. The second one is part of some kind of machine shop conspiracy, and the actual 123 one in the pic is toasted!
(11-07-2010, 02:45 PM)300D50 Wrote: I see the cast iron tranny! Wooo!

Showoff, getting shiney bling bling adapter plates... :p I'll show you... Big Grin

And those astro's SCREAM pedo, it's what the media puts in peoples heads daily...
Ifins ya need help, be sure to let me know. And I've got a spare 616 you can have for the right price as well...

Lol, well, theres nothing I can do about the media's unfair portrayal of panel trucks!
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

(This post was last modified: 11-07-2010, 04:42 PM by JB3.)
11-07-2010, 04:34 PM
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300D50 Offline
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#5
RE: Turbo 616 powered Astro Van build
Oh, and update needed on HRCS. It's not minitruck, but it's still awesome!

The iron one is toasted???! I feel bad now...
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
(This post was last modified: 11-07-2010, 04:54 PM by 300D50.)
11-07-2010, 04:52 PM
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JB3 Offline
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#6
RE: Turbo 616 powered Astro Van build
(11-07-2010, 04:52 PM)300D50 Wrote: The iron one is toasted???! I feel bad now...

no no, the middle one is toasted, the 123 5-speed. I threw it in for size comparison basically. I have not opened it up yet, I have a crackpot theory that I can fix it. Big Grin

As far as I know, the iron box is in good shape.
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

(This post was last modified: 11-07-2010, 05:01 PM by JB3.)
11-07-2010, 05:00 PM
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ben2go Offline
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#7
RE: Turbo 616 powered Astro Van build
This gonna be a good build.Very different IMHO.I promise not to post Pedo Bear's seal of approval in this thread. Angel I just wanna ask one favor.Would you post up some pics of the 616 after you get it out and cleaned up,please?
1990 Mercury Blue Max Cougar 3.8L with Automatic
Future OM617 Super Turbo Diesel Conversion with T56 6 Speed Manual
11-07-2010, 05:04 PM
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JB3 Offline
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#8
RE: Turbo 616 powered Astro Van build
(11-07-2010, 05:04 PM)ben2go Wrote: This gonna be a good build.Very different IMHO.I promise not to post Pedo Bear's seal of approval in this thread. Angel I just wanna ask one favor.Would you post up some pics of the 616 after you get it out and cleaned up,please?

will do. actually, whats ridiculously ironic about that whole thing is I actually drove an ice cream truck in high school, paper hat, suspenders, and all. A 1965 Ford Good Humor pickup truck. Big Grin From that experience, the largest consumers if ice cream on my route were actually not kids, but auto shop techs!

The truck was so old that it did not have a recording, it had a series of little bells and a hanging wand, and I was supposed to ding them when I pulled in. All these burly greasy guys would come lumbering out and purchase ice cream during the warm months.
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

(This post was last modified: 11-07-2010, 05:10 PM by JB3.)
11-07-2010, 05:10 PM
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300D50 Offline
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#9
RE: Turbo 616 powered Astro Van build
Inverse of pedobear then... old pedobears preying on the ice cream man... Tongue
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
11-07-2010, 05:14 PM
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DeliveryValve Offline
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#10
RE: Turbo 616 powered Astro Van build
Nice kit. It's looking like a cool project!


(11-07-2010, 01:57 PM)dropnosky Wrote: .....I was saying in the other thread, but ill cover it here again, the fully loaded generation 2 astro is actually only 600 lbs heavier than the 123 mercedes. This is a smaller, lighter generation 1 cargo version of the astro. ...

That includes fuel? My parent's '85 had a 27 gallon gas tank. So that translates to about 162 lbs of gas or 189 lbs of diesel.

I wonder what kind of fuel mileage you'll get after the swap. My parent's '85 had a Rochester Quadrajet 4-Barrel carburetor 4.3 and it got about 22 on the highway and probably about 15 around town.



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Gota love Mercedes Diesels!



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11-07-2010, 09:22 PM
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ben2go Offline
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#11
RE: Turbo 616 powered Astro Van build
(11-07-2010, 05:10 PM)dropnosky Wrote: will do. actually, whats ridiculously ironic about that whole thing is I actually drove an ice cream truck in high school, paper hat, suspenders, and all. A 1965 Ford Good Humor pickup truck. Big Grin From that experience, the largest consumers if ice cream on my route were actually not kids, but auto shop techs!

The truck was so old that it did not have a recording, it had a series of little bells and a hanging wand, and I was supposed to ding them when I pulled in. All these burly greasy guys would come lumbering out and purchase ice cream during the warm months.

HAHA!A lady,Mrs.Todd, that taught me social studies in junior high school, opened Todd's ice cream in our area and run good humor out of business.




(11-07-2010, 09:22 PM)DeliveryValve Wrote: I wonder what kind of fuel mileage you'll get after the swap. My parent's '85 had a Rochester Quadrajet 4-Barrel carburetor 4.3 and it got about 22 on the highway and probably about 15 around town.


I gotta have a guess at this.High 20's to low 30's mpg.Probably low 20's hauling around town. Cool

Dang it!Now I'm looking at Astros.Oh well,I do have kids. Rolleyes
1990 Mercury Blue Max Cougar 3.8L with Automatic
Future OM617 Super Turbo Diesel Conversion with T56 6 Speed Manual
11-07-2010, 11:27 PM
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JB3 Offline
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#12
RE: Turbo 616 powered Astro Van build
ive been going nuts cause I moved and the van is like 450 miles from me now, but I have it all figured out.

I will finally be able to get my hands on it, im gonna fly up there next friday and drive this thing back home all that distance. Hopefully it makes it. Big Grin

I already mailed a jack, tools, and a sleeping bag to the place the van is parked, so I should be good to go, or at least be able to change the tires as they blow.

On another note, I can't believe how cheap it is to fly these days! I was trying to U-ship the van for a while, and the cheapest quote I could get was like 300-400 bucks, but if I FLY there, it only costs 58 bucks! With bus and commuter fare to get me to the airport and to the van, its a grand total of only 75 or 80 bucks to put me in the drivers seat at 9 am in the morning.
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

11-24-2010, 02:45 PM
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ben2go Offline
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#13
RE: Turbo 616 powered Astro Van build
Gud luck.
1990 Mercury Blue Max Cougar 3.8L with Automatic
Future OM617 Super Turbo Diesel Conversion with T56 6 Speed Manual
11-24-2010, 03:27 PM
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300D50 Offline
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#14
RE: Turbo 616 powered Astro Van build
Have fun with your pat-down and tebag grab! :mrgreen:
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
11-24-2010, 06:40 PM
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ben2go Offline
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#15
RE: Turbo 616 powered Astro Van build
I hope your pat down comes with a happy ending.Maybe the guy won't be to ugly. [Image: emot95.gif]
1990 Mercury Blue Max Cougar 3.8L with Automatic
Future OM617 Super Turbo Diesel Conversion with T56 6 Speed Manual
11-25-2010, 12:03 AM
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willbhere4u Offline
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#16
RE: Turbo 616 powered Astro Van build
Just make sure when yer dun to say (was it as good for you as it was for me)
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
11-25-2010, 12:08 AM
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300D50 Offline
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#17
RE: Turbo 616 powered Astro Van build
Moan a bit, it turns em on :p
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
11-25-2010, 12:47 AM
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JB3 Offline
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#18
RE: Turbo 616 powered Astro Van build
You people are sick. If it looks like im going to be developing that close a relationship with the TSA, I think ill find another way to get the van! Big Grin

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

(This post was last modified: 11-29-2010, 09:24 AM by JB3.)
11-26-2010, 10:45 PM
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300D50 Offline
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#19
RE: Turbo 616 powered Astro Van build
Redundancy is nice, TSA = Transportation Security Administration. :p
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
11-26-2010, 10:54 PM
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JB3 Offline
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#20
RE: Turbo 616 powered Astro Van build
(11-26-2010, 10:54 PM)300D50 Wrote: Redundancy is nice, TSA = Transportation Security Administration. :p

Edited so it never happened Smile
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

11-29-2010, 09:24 AM
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300D50 Offline
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#21
RE: Turbo 616 powered Astro Van build
Wow, you are SUCH a sly one! I saw all the TSA acronym bs you had hear a day ago... Tongue
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
11-29-2010, 12:58 PM
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Captain America Offline
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#22
RE: Turbo 616 powered Astro Van build
So did I

1982 300D Turbo ... 3,6xxlbs, No fan, No AC, Hood Stack, No ALDA, No rear bumper and stuffed front, A/W Intercooled, Injectors by Greezer and HUGE Pre-Chambers with help from OM616 & Simpler=Better, Fuel Cranked up, 60 Trim Compressor wheel, EGT, EMP, Boost 50" Rigid Radius bar on roof Aux tank for a total of 48 Gal Of Diesel! Odyssey PC-1750 Battery in trunk, 27"x8.5"/R14 Maxxis BigHorn Mud Terrains, In June '14 issue of Off Road Mag

AX15 Jeep Trans swap in progress....

11-30-2010, 04:45 PM
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JB3 Offline
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#23
RE: Turbo 616 powered Astro Van build
(11-29-2010, 12:58 PM)300D50 Wrote: Wow, you are SUCH a sly one! I saw all the TSA acronym bs you had hear a day ago... Tongue

ha ha, whats sly about that? Decided to delete it and there were no responses at the time. Fair game in my book, new response is simpler and less likely to promote further sick commentary. Big Grin
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

11-30-2010, 09:44 PM
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300D50 Offline
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#24
RE: Turbo 616 powered Astro Van build
(11-30-2010, 09:44 PM)dropnosky Wrote: new response is simpler and less likely to promote further sick commentary. Big Grin

You know you enjoyed it though.Rolleyes
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
11-30-2010, 09:49 PM
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300D50 Offline
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#25
RE: Turbo 616 powered Astro Van build
Didya ever get through the TSA screening?
I was waiting all friday for the pedovan, thought maybe you were put on the "no fly" list :p

Bad pun. Very bad pun...
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
12-05-2010, 07:05 AM
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JB3 Offline
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#26
RE: Turbo 616 powered Astro Van build
the issues with that vehicle made it necessary for me to run from the following snow storms in a straight shot. left at 4:30 in the morning to take the bus down to the airport. Flight was fine, no problems with the TSA. I managed to get to the dealership at like 11am after riding buses all over creation, then the dealer and I argued for a while since they stole my spare tires and mounted them on other vehicles, of course they maintained that I never brought them. Rolleyes

Finally got them to give me some shitty shitty spares since mine were "missing"
They also accidentally broke the hood pull during their "fluid top off", so I could not check fluids at all on the drive. Overall, it was the usual dealer dog and pony show.

The van has some steering issues, bald tires with steel showing on the fronts, brake issues, no exhaust, doors that come open on the highway without warning, and a host of other problems. Despite all this and a kind of pogo-stick ride on the rear, it made it all the way down without a singe issue, apart from the doors opening repeatedly, I had to ratchet strap them in place.
It was really taxing to keep that thing in a straight line though. The front suspension components are relatively tight considering, but the front tires are almost visibly toed in, and there is huge looseness in the steering, so it was a nighmare to keep it rolling in a straight line without developing am overcorrection swerve that would flip the van.
I drove through a few preliminary small snow storms that were not sticking, but the thing would have been flat impossible to drive with even the slightest snow on the road, so I kept going and made no stops

Now I can finally work on this though. The weight and gearing of the vehicle look very favorable compared to the 240. This model is supposedly about 3500 lbs, and has a 3.45 rear end. I parked it next to the 240, even the EXT model which this is, is like a foot shorter than the mercedes, but the whole vehicle is way wider. Its far more of a square, I like the layout of it personally, internally there is a lot of space.
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

(This post was last modified: 12-05-2010, 08:08 AM by JB3.)
12-05-2010, 08:02 AM
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300D50 Offline
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#27
RE: Turbo 616 powered Astro Van build
Bwahahaha, doors opening at speed, that hada be fun Big Grin
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
12-05-2010, 03:06 PM
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JB3 Offline
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#28
RE: Turbo 616 powered Astro Van build
ive been nailed to the wall with other obligations, but despite the coldness of the day, made time today to make progress.

engine and 5 speed came out of the 240-


.jpg   240engineout1.jpg (Size: 94.93 KB / Downloads: 8,697)

.jpg   240engineout2.jpg (Size: 98.22 KB / Downloads: 8,246)

5-speed removed and put aside for the other car. Needs a little work, and definitely a coat of paint.
Found an issue with the adapter, which designed for a 5cly, will not bolt to the 4cyl with the stock oil filter housing. I will have to make some kind of remote filter.


.jpg   adapterproblem2.jpg (Size: 86.25 KB / Downloads: 5,502)

.jpg   adapterproblem1.jpg (Size: 83.75 KB / Downloads: 6,056)

The problem illustrated compared to a 5cyl thats also in the garage- I thought at first I could just switch housings, but theres not enough room and it will hit the injection pump. It will have to be a remote oil filter.


.jpg   5yloilfilter.jpg (Size: 87.81 KB / Downloads: 5,431)

.jpg   adapterproblem3.jpg (Size: 88.84 KB / Downloads: 6,090)

One other issue as well, I pulled the oil filter, and the plate fits great after that, but there appears to be a depth issue to resolve as well. the custom flywheel hits the mounting bolts for the plate when installed. I will have to space it out, or use different hardware or something. Should not be too big a problem.
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

12-19-2010, 09:05 PM
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300D50 Offline
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#29
RE: Turbo 616 powered Astro Van build
Leme know if you need help with the remote filter, seems like it's easy enough to do. Smile

As for flywheel hitting fasteners, just shave down the heads a bit as needed with a grinder/lathe.

All in all, looks like you're going good so far.
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
12-19-2010, 09:36 PM
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JB3 Offline
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#30
RE: Turbo 616 powered Astro Van build
(12-19-2010, 09:36 PM)300D50 Wrote: Leme know if you need help with the remote filter, seems like it's easy enough to do. Smile

As for flywheel hitting fasteners, just shave down the heads a bit as needed with a grinder/lathe.

All in all, looks like you're going good so far.

I might be able to space the oil filter straight out from the block to provide the clearance needed, depends on the room inside the hatch. I have a feeling the oil filter might not work like that. Thanks for the offer, I might take you up on that depending on how I resolve this.

I want to make sure that the flywheel is at the correct depth in relation to the adapter plate, different fastners would work, and also I can probably use an extra exterior mounting ring on the inside of the flywheel to space it out a bit. Dont think it will be too bad to deal with, hopefully with minimal work.
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

12-20-2010, 08:03 AM
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Diesel-Wiking Offline
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#31
RE: Turbo 616 powered Astro Van build
awesome project!
*1984 Mercedes S123 300TD turbodiesel*
*1993 BMW 525tdsT*
*1990 BMW 524 turbodiesel*
*1983 BMW 745iA e23*
*1969 BMW 3.0csl racecar*
12-21-2010, 02:53 PM
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ben2go Offline
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#32
RE: Turbo 616 powered Astro Van build
The wife wants a van and I found a pristine 1990-92 Astro conversion van for $1100.I should consider buying it and doing a swap in it.The guy can't sell the van because it's a 4 cylinder and it's a brownish gold color.My Cavalier is the same color so I can over look that,but that shitty 2.5L gasser has gotta go.If it had a factory 2.8 or 4.3 conversion,it would have been gone.
1990 Mercury Blue Max Cougar 3.8L with Automatic
Future OM617 Super Turbo Diesel Conversion with T56 6 Speed Manual
12-21-2010, 02:58 PM
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JB3 Offline
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#33
RE: Turbo 616 powered Astro Van build
(12-21-2010, 02:53 PM)Diesel-Wiking Wrote: awesome project!

thanks!
(12-21-2010, 02:58 PM)ben2go Wrote: The wife wants a van and I found a pristine 1990-92 Astro conversion van for $1100.I should consider buying it and doing a swap in it.The guy can't sell the van because it's a 4 cylinder and it's a brownish gold color.My Cavalier is the same color so I can over look that,but that shitty 2.5L gasser has gotta go.If it had a factory 2.8 or 4.3 conversion,it would have been gone.

you should! We'd both get done faster if we were racing eachother! Big Grin
I ran into the 20 year DOT/EPA issues though, at least in this area, I ended up selling the 94 to a junkyard and grabbing another one, an 89, which got me around any potential issues with that. You should see if there are any state or federal issues in your area with passing emissions. For instance, the 94 would have had to go through an emissions test in CT, a possible registry state for it, and I was going to have serious problems with a diesel in it actually legally driving around. Just a potential PITA I decided was not worth dealing with, so found the 89, which is actually in much better condition.
got the adapter clutch and starter and here are some comparison pics-

It will be using an 11 inch Chevy K1500 clutch, and a 99 Ford 5.0 starter. Starter is WAY smaller, ill be interested to see how it performs-
starters-

.jpg   fordstarter.jpg (Size: 84.89 KB / Downloads: 6,524)

clutch and flywheel comparisons, obviously the K1500 clutch is much larger, although overall weights between the two seem to be pretty close-


.jpg   clutchcompare1.jpg (Size: 74.55 KB / Downloads: 5,417)

.jpg   clutchcompare2.jpg (Size: 71.22 KB / Downloads: 5,147)

.jpg   flywheelcompare1.jpg (Size: 66.68 KB / Downloads: 5,207)

also test fitted the custom manifolds, Rudolf_Diesel did an awesome job on this exhaust, only a little filing on the stud holes on both manifolds is needed to make it fit almost perfectly. As it stands, all bolts go in with the exception of one and another being a hair tight-
They will come off and be painted with the adapter plate on final assembly-

.jpg   manifolds1.jpg (Size: 74.92 KB / Downloads: 5,257)

.jpg   manifolds2.jpg (Size: 70.17 KB / Downloads: 5,558)

The feared heat interference with the starter solenoid being too close to the turbo is a non issue with this ford starter being so small and pointing in the other direction. Unfortunately, the turbo is rusted fast to its original manifold, so I could not test fit it on the custom manifolds at the moment, but I put it on on the original manifold and its not going to be a problem-


.jpg   starterclearance.jpg (Size: 79 KB / Downloads: 7,008)

Heres where the plate for the remote oil filter will need to fit-


.jpg   remoteoil4.jpg (Size: 71.23 KB / Downloads: 5,157)




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

(This post was last modified: 12-23-2010, 12:22 PM by JB3.)
12-23-2010, 12:06 PM
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ben2go Offline
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#34
RE: Turbo 616 powered Astro Van build
Will that flywheel bolt up to an OM617?Looks like the bolt holes need to be drilled a little bigger.
1990 Mercury Blue Max Cougar 3.8L with Automatic
Future OM617 Super Turbo Diesel Conversion with T56 6 Speed Manual
12-23-2010, 05:35 PM
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JB3 Offline
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#35
RE: Turbo 616 powered Astro Van build
yeah, its just a trick of the picture I think, it bolts up well. The MB flywheel has some shininess where the bolt seating surfaces were but the holes on both are the same size
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

12-24-2010, 06:19 PM
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ben2go Offline
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#36
RE: Turbo 616 powered Astro Van build
(12-24-2010, 06:19 PM)dropnosky Wrote: yeah, its just a trick of the picture I think, it bolts up well. The MB flywheel has some shininess where the bolt seating surfaces were but the holes on both are the same size

Sweet deal.Thanks for clearing that up.Please post up what you do for a pilot bearing/bushing.
1990 Mercury Blue Max Cougar 3.8L with Automatic
Future OM617 Super Turbo Diesel Conversion with T56 6 Speed Manual
(This post was last modified: 12-24-2010, 10:08 PM by ben2go.)
12-24-2010, 10:08 PM
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garage Offline
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#37
RE: Turbo 616 powered Astro Van build
Whats up with this project drop?
I was real excited to see all this come together.
1987 300D: EGR Delete, ARV Delete, Cold Air Intake...
02-26-2011, 03:43 PM
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JB3 Offline
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#38
RE: Turbo 616 powered Astro Van build
(02-26-2011, 03:43 PM)garage Wrote: Whats up with this project drop?
I was real excited to see all this come together.

Ive just been really busy with work and other obligations. Plus other factors like its cold and dark outside when I get out of work, and the older I get, the less inclined I am to working outside in the cold when I don't have to. Big Grin Looking forward to it staying lighter longer and warming up a bit to move forward faster.

I have been moving forward getting the van up to speed though, somewhat related to the swap. It needed some decent suspension work up front, and had a broken shackle in the rear for the leaf springs, so ive taken care of that and ball joints, tie rods, shocks, pitman arm, ect. All were loose or bad.
Inside ive repaired all the broken and missing stuff from the dash, and central console, ect. Its pretty simple electrically, with no features whatsoever, which should be nice for the swap, but even so, what was there was a total rats nest of tangled and crossed wires. For instance, the PO was running the blower motor by twisting wires hanging out of the dash, instead of replacing the 2 dollar switch from GM.

Also have done some body work, going to replace the passenger door since its damaged, and have been working to fix all the door handles. I had to cut through the top of the dented rusty hood to open it by accessing the latch from the back side.

Once that was done, I could only find this replacement as the nicest hood in the yard.

.jpg   fishmanhood.jpg (Size: 78.87 KB / Downloads: 516)

Needless to say, that lettering had to go
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

(This post was last modified: 02-28-2011, 09:40 AM by JB3.)
02-28-2011, 09:01 AM
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willbhere4u Offline
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#39
RE: Turbo 616 powered Astro Van build
Whats up with the space between> THE ____ FISHMAN blue?

How much for the women and children?
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
02-28-2011, 11:45 AM
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JB3 Offline
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#40
RE: Turbo 616 powered Astro Van build
(02-28-2011, 11:45 AM)willbhere4u Wrote: Whats up with the space between> THE ____ FISHMAN blue?

How much for the women and children?
Big Grin

There was an outline of a big graphic or magnet of a fish, must have been pretty neat, cause it was long gone, somebody already carefully peeled it off, leaving that space.

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

02-28-2011, 12:50 PM
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willbhere4u Offline
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#41
RE: Turbo 616 powered Astro Van build
lol that's awesome!
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
02-28-2011, 01:21 PM
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garage Offline
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#42
RE: Turbo 616 powered Astro Van build
Yeah im sure all that snow would keep me inside too!!

1987 300D: EGR Delete, ARV Delete, Cold Air Intake...
02-28-2011, 03:38 PM
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JB3 Offline
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#43
RE: Turbo 616 powered Astro Van build
hehehe, took some doing and searching, but look what I finally am getting my hands on! Big GrinBig GrinBig Grin-

This is an OEM Chevy Astro 5-speed collection of parts. Its based off a (bad) T5 tranny, but includes special shifter, clutch apparatus, hydraulic slave and master, flywheel, driveshaft, mounts, and everything else from a factory 5-speed astro. Didn't think id ever find one, but they do exist, seem to be rarer than a 300D 4-speed euro-spec in this country, these parts are coming with a whole other van though. Had to buy the van to get the parts, but it was a super deal, so not too bad.

This guy has all kind of rare stuff, the other van is an AstroRS, or Rally sport. Evidently they have 4.10 gears, oil and tranny cooler, custom rims, heavy sway bars and hard suspension. This is combined with a kind of mini van A-team paint job. Ill have to see this thing is person first, need to fix the brakes to resell is though.

I have to rebuild the tranny, but all this other stuff is like gold, especially the clutch apparatus and shifter setup.

Also comes with the clutch and all, so I can compare with the kit. The T5 looks like it will use the exact same mount points as the NV3500.


.jpg   astro5speed.jpg (Size: 7.54 KB / Downloads: 4,678)

.jpg   astro5speed3.jpg (Size: 8.07 KB / Downloads: 4,413)
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

(This post was last modified: 05-06-2011, 05:49 PM by JB3.)
05-06-2011, 05:41 PM
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JB3 Offline
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#44
RE: Turbo 616 powered Astro Van build
(05-06-2011, 05:41 PM)dropnosky Wrote: Had to buy the van to get the parts, but it was a super deal, so not too bad.

This guy has all kind of rare stuff, the other van is an AstroRS, or Rally sport. Evidently they have 4.10 gears, oil and tranny cooler, custom rims, heavy sway bars and hard suspension. This is combined with a kind of mini van A-team paint job. Ill have to see this thing is person first, need to fix the brakes to resell is though.

Check this thing out, I love these crazy performance editions of work and family vehicles.

Astro Rally Sport-
Front and rear stiff sway bars and hard shocks
200 hp 4.3 high output V6
4.10 rear end
oil and tranny coolers
factory paint and body scheme and matching rims


.jpg   astrors1.JPG (Size: 77.13 KB / Downloads: 535)
.jpg   Astrors.jpg (Size: 84.66 KB / Downloads: 1,857)

Project related-
T5 is apart and being rebuilt, excellent selection of rebuild kits out on the market for that tranny.
Work van has a failing fuel pump and is down for the count, ive started fiddling with the pedal setup. Potential problem is that pedal space is limited based on size of your foot, I might have to cut down the brake pedal to avoid pushing it in when I push in the clutch eventually. I measured and there is less than an 8th of space between the drive side of the brake pedal and the wheel well. Could be a major problem if I go to push in the clutch fast and catch the brake.
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

(This post was last modified: 07-06-2011, 11:06 AM by JB3.)
07-06-2011, 11:00 AM
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ben2go Offline
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#45
RE: Turbo 616 powered Astro Van build
Rework the hump to gain some foot well space.
1990 Mercury Blue Max Cougar 3.8L with Automatic
Future OM617 Super Turbo Diesel Conversion with T56 6 Speed Manual
07-06-2011, 07:08 PM
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srbsmartie Offline
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#46
RE: Turbo 616 powered Astro Van build
Any more progress?
I have an 02 Astro passenger van that I want to swap an OM603/606/CDi into. What made you use the 616? Was it ease of packaging, or simply because you already had it?
I would like to use the MB 722.6 transmission if I can find one, I have a 4L60E in the van now but would like to just swap engine and trans together.
Craig
Craig
"Mighty Smart"-2008 smart fortwo (the littlest Mercedes Big Grin )
2002 Chevy Astro- really needs an STD!
(This post was last modified: 09-08-2011, 10:21 PM by srbsmartie.)
09-08-2011, 10:12 PM
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JB3 Offline
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#47
RE: Turbo 616 powered Astro Van build
(09-08-2011, 10:12 PM)srbsmartie Wrote: Any more progress?
I have an 02 Astro passenger van that I want to swap an OM603/606/CDi into. What made you use the 616? Was it ease of packaging, or simply because you already had it?
I would like to use the MB 722.6 transmission if I can find one, I have a 4L60E in the van now but would like to just swap engine and trans together.
Craig

I had the engine in hand and its very reliable, and the weight of my cargo van is about the same as the 240 the engine came out of, so I figured what the hell.

Ive been moving real slow. Ive got a small business and the 89 is our only delivery cargo van, so its tough to take it out of service for very long and my free time is limited, but thats a complaint we all have. Big Grin

However, ive been looking around for a spare subframe that I can work on while the van is in service. I should be able to install the engine and trans on that frame and then switch them once the 25 year EPA restriction is passed.

In RI, I was told by DMV personnel, (whether or not this is true remains to be tested) that I could legally install my 1980 240D engine into my 1989 work van, re-title it as diesel, and retain a copy of the 1980 title, whereas the van would them be subjected to inspection regulations for the 1980 model year for diesels, as long as I could prove where and when the engine originated.

However, since I need the van daily, have not been able to find that statement in writing anywhere, and have been told the exact opposite by everyone else, and would be pissed to have to park it for years if I do the swap and find it un-inspectable, ive decided to wait until I pass the magic 25. Gas V6 probably has a few more years, although its definitely getting tired.

RI law-
A motor vehicle twenty five (25) model years old or older will be given the
required safety and emissions test for the same fees as other vehicles but will not
be denied the approval if the owner fails to complete any emission repairs. The
vehicle owner may choose either the TSI OR TRANSIENT emissions test.


They inspect it, but if you fail emissions, it still gets passed. When I inspected the 84 300D I used to own, the emissions inspection is totally optional, you can get if for curiosity sake, but its not necessary. 2014 here I come. Actually 2013, thats when I get a re-inspection which will push me past the bar.

I should be able to work on a spare subframe over in the corner of the shop in the meantime though.
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

09-09-2011, 08:28 AM
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JB3 Offline
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#48
RE: Turbo 616 powered Astro Van build
This weekend removed subframe, engine and tranny from recently sourced parts van.

Heres the van, subframe looked good, and it has a rebuilt tranny I can sell. Engine has about 380K on it, but apparently still runs. Ill try and sell that too

[Image: vansubframe1.jpg]

Removed a total of 4 out of 6 bolts, and body comes right off. (front two were rusted out)

[Image: vabsubframe2.jpg]

The subframe looks in OK shape, will need rust repair in about 8 places, especially the front bolt points, neither of which are there any more

[Image: vansubframe3.jpg]

Engine and tranny on these vans is over on the passenger side quite a bit, no wonder shifter apparatus for manual is so far over to the driver side

[Image: vansubframe4.jpg]

rusted mount position up front, this is a problem, I have no idea what its supposed to look like. Big Grin Just checked on the running van, and its got the same problem. Hopefully ill get some pics from some other astro owners not in a rusty area

[Image: vansubframe5.jpg]

Waiting on tranny to be done, local tranny shop and i are working on adapting a camaro gearbox to the astro bell housing and shifter apparatus. Original T5 was cooked big time
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

(This post was last modified: 10-03-2011, 03:24 PM by JB3.)
10-03-2011, 03:21 PM
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ben2go Offline
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#49
RE: Turbo 616 powered Astro Van build
I thought the Asstros were full framed like an S-Ten.
1990 Mercury Blue Max Cougar 3.8L with Automatic
Future OM617 Super Turbo Diesel Conversion with T56 6 Speed Manual
10-03-2011, 05:20 PM
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JB3 Offline
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#50
RE: Turbo 616 powered Astro Van build
(10-03-2011, 05:20 PM)ben2go Wrote: I thought the Asstros were full framed like an S-Ten.

According to wikipedia, the early vans are using the front suspension from the GM B-body station wagons, like the caprice. I don't know if its a stand alone subframe made for just these vans or not, but the rest of the van is a quasi unibody with a pair of fiberglass leaf springs in the rear.

I was surprised too, I thought they just dropped a van body on an S-10 frame, but its apparently been adapted from the large station wagons, which would explain why the vans are so wide. Then they took the S-10 drivetrain to power them

Design certainly makes it easy to deal with the subframe, its balanced enough that you can grab the back bar and push it around like a wheelbarrow

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

(This post was last modified: 10-03-2011, 06:36 PM by JB3.)
10-03-2011, 06:31 PM
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