BRUCE'S MERCEDES DIESEL SL PROJECT

DROP OFF DATE: Monday, ---------- (NEEDS TO BE HAULED)

TARGET DATE: I will be back for Monday, ---------- (Probably will still need to be hauled, unless all motor wiring already working by time sending in to shop)

RECIPIENT VEHICLE DETAILS:
#  1991 Mercedes-Benz 300SL-24 convertible (r129.061) -- recipient car
#  722.500 transmission -- 5-spd hybrid box (1st-4th are pneumatic, 5th is electronic)
   #  Will provide alternate tranny in case 722.500 proves unusable
     #  722.418 4-spd from donor car (pneumatic)

DONOR VEHICLE DETAILS:
#  om602.962 diesel 2.5l turbo inline 5-cylinder motor
#  1993 Mercedes-Benz 300D 2.5L turbo sedan (w124.128) -- diesel donor car
   #  available for reference or parts, under carport at side of house, if it comes to that

CAUTIONS:
#  SYSTEM HAS MOST FLUIDS DRAINED:
   #  NO ATF
   #  PARTIALLY DRAINED POWER STEERING
   #  NO OIL
   #  NO COOLANT (normal drain, block not drained)
#  DO NOT TRY TO OPERATE/REMOVE ROOF
   #  Left rear roof lock hydraulic mechanism is broken (have part, will fix later when I send all eight out to Oregon for cylinder/seal refurbishing)

NOTES:
Comparison/Sibling Vehicles:
#  1991-1996 300SD/S350 [w140.134]: S-Class (w140 chassis) diesel models (om603 6cyl)
#  1990-1993 300D [w124.128]: E-Class (w124 chassis) diesel models (om602 5cyl)
#  1990-1993 300SL [r129.061]: SL-Class (r129 chassis) gasoline models (m104 6cyl )
#  r129 SL is a blend of a shortened w124 chassis and the w140 systems

WORK TO BE DONE:
PHASE I:
#  ENGINE DOES NOT QUITE FIT with existing mounts/mount arms and crossmember - too far forward (maybe), too high (definitely)
   #  NEED TO MAKE IT FIT -- ideally use hydraulic mounts from diesel motor (egg-shaped), but gas motor mounts may be ok (hamburger shaped) as long as will damp vibrations enough -- either set of mount arms may work? -- maybe other sibling models' arms and/or mounts might work?
   #  PREFER MINIMAL ALTERATIONS TO CAR STRUCTURE WHERE POSSIBLE/REASONABLE -- safety and reliability are key
   #  Note that tranny mount has an available existing pre-threaded mount point forward of original (model has two lengths of driveshaft depending on tranny used, this one is the longer tranny). Not sure if this will be useful, but it is there.
   #  DRIVELINE ALTERATION/REPLACEMENT IF NECESSARY due to engine being four (4) inches forward
      #  Will provide front half of propeller shaft from donor w124, in case that is useful
   #  Shift linkage rod extension, if required

#  CUSTOM COOLANT HOSES (presumably)
   #  Some other r129 models have radiators with better connector alignment to om602 motor (but presumably quite a bit more costly to go this route of getting another radiator, versus coolant hoses?)
      #  om602 diesel main hoses are top-left, bottom-right
      #  Existing radiator is left side for both
      #  Some 500 SL / 600 SL models have top-left, bottom-right; specific models unclear

#  FUEL TANK RESEAL (sublet?) -- needs to be cleaned and then be "resealed"
   #  Reseal is to cover over existing galvanization (bad for diesel fuel system) -- a reseal by radiator repair place is supposed to take care of this

#  FUEL LINE FLARES -- need to alter hardline ends to work with fuel hose lines

PHASE II:
#  AIR INTAKE & FILTER LOCATION/MOUNT
   #  Planning to use the right-side intake funnel available for most other SL models to draw in from side of radiator area (as current version draws from left side)

#  OIL COOLER LOCATION/MOUNTING/ALTERNATES?
   #  Some other SL models have a nice oil cooler which goes under the radiator (there is a spot for this on my SL, just is empty)
   #  Not sure whether worth the cost to changeover to the SL cooler or finagle the diesel oil cooler somehow.  I can't work with the crimped hoses, but I think you can, so that opens the option more. Going with an SL oil cooler would probably be ideal, but cost is the concern from when I've priced them online

#  CUSTOM EXHAUST? (sublet?)
   #  Have existing exhaust from both vehicles to reuse parts where possible/cheaper
   #  Does it actually need a custom new one, or can it reuse existing?
      #  Many folks have said I can use the existing SL exhaust as is?
         #  What about the catalytic converter?  Mufflers?  Resonator?
      #  Still would need a flex connector, of course
   #  Ideally would like exhaust large enough (3 inch?) to avoid any backpressure issues if/when exhaust manifold/EGR is replaced later on with less-restrictive
      #  Many folks have suggested just going with a straight through pipe?

WORK BRUCE IS DOING: unless/until I get stuck!
#  WIRING: engine/EDS, preglow, starter, shutoff, instrument panel, tachometer
#  VACUUM LINES
#  FUEL SYSTEM: hoses, hard lines, tank strainer, filler neck
#  CONVERTIBLE TOP: hydraulics refit, new main window, fix small tear

FUTURE WORK:
#  SUSPENSION ADJUSTMENTS/TUNING
   #  Maybe spring replacements -- occasionally bottoms out in front
   #  Would like it to be just a little higher, so doesn't scrape on curbs and such so much
#  A/C -- including removing fuel cooler interface
#  EGR removal
#  SEATS: repair motors/switches (or replace/upgrade seats to 1996-2001)
#  DOOR PANELS: upgrade to 1996-2001 styling (add on side airbags?)
#  CUSTOMIZATIONS: hot/cold water dispenser, A/C to trunk, wifi, inverter for plugging in electronics, eliminate antenna mast (change to internal/concealed antenna)
#  HYBRID ADAPTATION: such as Dr. Perry's wheel hub add-on motor project
#  Open to suggestions/advice