Turbo 616 powered Astro Van build

JB3

Superturbo

1,795

10-28-2011, 08:41 PM #68

Heres another bunch of pics

The clutch showed up, so I got to put the engine and gearbox together using the 4x4 lab kit, and boy, Im definitely of the opinion that that kit was worth it. Just went together so nice, and finish quality is great.

Heres the flywheel bolted up, I was mistaken, i did not need to block it off the crank shaft, the tolerances are about 2mm behind the flywheel

[Image: flywheel1.jpg]

The new clutch I got was effectively the same as the one I purchased way back for a K-1500 except for the splines and a different pilot bearing. heres a pic of the MB to Chevy pilot bearing adapter from 4x4 labs. I ended up using the actual bearing that came in the 1500 kit, and not the bushing that came in the new kit.

[Image: pilotbearings.jpg]

Bearing adapter goes through the new flywheel into the crank, and seats nicely with the new pilot bearing in. I really was pleased with how they rigged this up

[Image: pilotbearingbushinginstalled.jpg]

[Image: pilotbearingbushinginstalled.jpg]

Clutch installed, shift fork and release bearing installed- (i need the GM boot for the shift fork, and I might need to weld slave cylinder seating point for the shift fork, its slightly cracked)

[Image: astrot5releasefork.jpg]

Bolted up the gearbox, and here are a few pics of the 616 and the T5 next to the stock Astro 4.3 and auto-

[Image: 616vs431.jpg]

Here is the new motor laying in the subframe. I used the rear transmission mount point to locate where it should be, and there is good news and maybe possible bad news.
Good news is that the engine won't interfere with the steering apparatus as I was expecting, and there should be more than enough room up front for choosing a radiator.
Bad news it that its awful high, and might hit the top of the hatch. I might get real lucky though, I measured the 4.3 and the 616 and with the air cleaner on the 4.3, they are close in height, plus a little working room. Just have to see how it fits when the time comes and make adjustments then.
Also, draining the oil might be a pain, maybe ill change the drain location on the pan to the front Big Grin

Time to build motor mounts, passenger side should be a straight shot, drive side will have to come forward a bit. On the fence about using stock GM or MB mounts, any thoughts? The GM mounts are WAY easier to change. Also, should I rig up a bracket to include the engine shock?

pass side-

[Image: passmount.jpg]

driver side-

[Image: drivermount.jpg]

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