240 Diesel Engine Swap Parts List For The JY

[Yamahapro]

Hey everyone, I am keeping my eye out for another 240 diesel to show up at a local junkyard and if its a manual transmission, I was thinking about pulling everything I need to swap it in another 240. I think I can figure out what I need if the engine is in a 240, but if anyone know of any bits I might forget, your information is appreciated.

If a 740 shows up though, my question is what can I take that will swap? Is the transmission bellhousing the same? Can I take a crossmember and driveshaft from a regular 240? This is where I would totally be lost.

[v8volvo]

The D24T engine from a 740 TD can be installed pretty easily into a 200 series car IF that 200 car is already a diesel. But if you are starting with a gas 240, then you would really need a diesel 240 parts donor in order to bolt in any D24 or D24T engine. The 200 and 700/900 chassis are very different and share almost no parts: the 700 series mounts, driveline, crossmembers, etc are all incompatible with 240. Bellhousing is also different since the diesel engine mounts at a more vertical angle in the 7 vs the 2.

In short, gas 240 chassis + diesel 740 drivetrain parts won't get you enough to make a car bolt together. In order to bridge the differences, you would need many parts from a 240 diesel also. Preferably a complete donor but at minimum:

- 240 D24 oil pan, pickup tube, and dipstick
- 240 D24 bellhousing or complete M46
- 240 D24 engine mounts
- various fuel system, cooling system, cooling fan and shroud, electrical system parts
- edit: also need the 240 D24 style power steering pump bracket (740 style is stronger BUT interferes with path of upper rad hose so you need the 240 type), and air cleaner box and ducting if you want to use factory looking parts for that, and the coolant reservoir and windshield washer fluid reservoir and their mounting brackets/plumbing/wiring since those items are on the other side IIRC in a gas 240.

The trans crossmember and mount is the same as on the gas cars. This is true for both 2 and 7 series.

I think your Plan A of continuing to keep eyes out for a diesel 240 in the junkyard is best bet. If your plan is to swap into a gasser, then pull EVERYTHING complete from the car -- engine with trans, plus driveline, everything from the cooling system (240 diesel rads are NLA, rare to find used, and a gasser one won't be big enough!), and as much of the fuel system and electrical glow plug system as you can manage. Whatever extra all that stuff costs you to buy from the JY will pay you back many times over in making it easier to get your swap put together and sorted out.

Good luck! Gas to diesel swaps are fun, definitely some work, but not bad if you are organized and diligent about the details to ensure a well finished end product. It can be a great way to get both the car and the engine you want, if they didn't come paired that way naturally. For example turbodiesel swap into a later era 1990s 240 would be a nice move, as you can then get features like ABS, better interior materials, better HVAC system, non-crumbling wiring harnesses, and other updates that were never seen in the early '80s model years that the diesel option was limited to in North America.

[Yamahapro]

Wow that is amazing information. Thank you! I was thinking there wouldn't be much off of a 740 that would do me a lot of good. What would you recommend taking off of a 740 diesel if one showed up at the yards?

I agree pulling EVERYTHING from a 240 donor car is a great idea. Do it right the first time. And I LOVE your idea of putting it into a late model car! My idea would be if another diesel 240 shows up at the yard. I would spend the money to get everything I need and then wait for a cool 240 to show up on CL whether it be early or late. Just wait for something to show up and looks like it would perfect for a diesel engine. Maybe something cheap and non running but clean.

[v8volvo]

Originally Posted by Yamahapro

What would you recommend taking off of a 740 diesel if one showed up at the yards?

- complete D24T engine
- transmission as well, if it's a manual (the 740 ZF auto is also very nice but cannot be used in 240, whereas the 740 TD M46 can be used in 240 if you bolt on a 240 bell, and would be a good spare to have)

Not much else would be of any use to you if your plan would be to put them in a 240 chassis. Maybe glow plug system or at least glow plug relay, as a spare.

If the 740 is a 1986 model also get the engine crossmember and battery tray from it, as those are special improved 1986-only parts that a 740/760 owner would likely love to have as an upgrade to their 1983-1985! But they won't contribute to your 240 swap.