Turbo Fitment into 240

[DieselScout]

I received my D24T block back from the machinist yesterday.

Currently removing the old engine from my Sedan.

Doing a quick test fit of the turbo and exhaust manifold before removing engine.

Doesn't look like there will be enough room....the body/frame of the car and the automatic transmission cooler lines are interfering with the turbo placement.
The transmission mount is already removed and I'm using a jack to raise the transmission/engine back to level...not sure if this is affecting the perceived fitment complications.

What's the typical remedy?
Can these be fit without cutting into the body/frame and removing the transmission lines?


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[v8volvo]

What type of turbocharger is that? It's not a stock D24T turbo -- maybe a turbo from something else?

Typical fitment on a 240 chassis with a stock D24T turbo clears the frame rail no problem. Having fresh (not sagged) engine mounts helps too.

In the case of this different turbo you are using, I am not sure. If the compressor housing is larger than the stock turbo, then that could be the cause for frame rail interference.

A/T cooler lines are also not something I'm familiar with, as all the 240 TD installs I have done were in M46 cars, but at least those lines are flexible enough that they can be re-shaped and relocated as necessary. Shouldn't be an issue.

[DieselScout]

I think it's from a Mercedes of the same era (looks about the same size) but I think the turbine housing is a .42 or a .48 instead of .36

Is the stock A/R .36 turbo the largest that will fit in a 240 without modification?

[DieselScout]

Got the newly built D24T into the 240.
The stock turbo clears the frame rail by about 1/2" with new engine mounts.
No contact with frame rail, even when shaking the engine.
Will this touch the frame rail as the engine mounts break in?

The turbo oil drain/modified portion of the oil pan clears the power steering rack....just barley.
Looks to be a millimeter or two of space.
No contact when mildly shaking the engine, but it does tap the rack when moderately shaking the engine.

Should I place some rubber in between to act as a buffer?
Or is this lack of additional clearance going to cause issues down the road?

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[ngoma]

You're asking if the turbo and oil return line are going to bump into the frame and steering rack? Hard to make a definitive call on that based on your two photos because of possible parallax errors, etc. but at first glance to me seems like too close to risk it.

You can shake the engine by hand and say "It'll be OK" but know that rotational forces when under power will be much greater that what your hands can provide from pushing on the valve cover. Sticking scraps of rubber into the tight gaps is not the answer. Maybe solid motor mounts? Or maybe some shims between the rubber mounts and engine brackets? To raise the engine up some more?