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460 Diesel Conversion & AC Install
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Posted 10/30/2007 7:48 PM
jordanb
Regular




Date registered: Sep 2007
Location: Toronto, Canada
Vehicle(s): 1986 560 SL; 1985 280 GE LWB
Posts: 57
50
460 Diesel Conversion & AC Install

I am considering replacing the gas engine on my '85 280 GE with a 617A engine and have some air conditioner related questions:

1) What is the suggested solution to mount AC comperssor on a 617A engine (please note that my G already has AC)?; and
2) What type of comperssor would you suggest?

Thanks!
#94241
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Posted 10/30/2007 9:37 PM
dai
Expert




Date registered: Apr 2006
Location: Oregon USA
Vehicle(s): 300GD 300TD BMW R100RS Landini 80F
Posts: 2110
2000
Re: 460 Diesel Conversion & AC Install

Rotary compressor, and use the search function at the top of the page. Look for posts by Stevesmith. He has the hot setup/bracket. You will find photos and a lot of info. Do a search on the benzworld forum as well. This was covered there too.

-Dai
#94249 - in reply to #94241
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Posted 10/30/2007 9:40 PM
Kuzuki

Date registered: Dec 1899
Location:
Vehicle(s):
RE: 460 Diesel Conversion & AC Install

Hi Jordanb,

here is pic of the setup

Mike


Edited by Kuzuki 10/30/2007 9:44 PM




(30_1363769_1210200411124AM.jpg)



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Attachments 30_1363769_1210200411124AM.jpg (47KB - 28 downloads)
#94250 - in reply to #94241
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Posted 10/31/2007 7:15 AM
jordanb
Regular




Date registered: Sep 2007
Location: Toronto, Canada
Vehicle(s): 1986 560 SL; 1985 280 GE LWB
Posts: 57
50
RE: 460 Diesel Conversion & AC Install

Thanks!
#94310 - in reply to #94250
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Posted 6/30/2008 1:55 PM
NOPEC
Extreme Veteran




Date registered: Feb 2008
Location: Babylon, Long Island, NY
Vehicle(s): 1985 Mercedes 300GD
Posts: 374
300
Re: 460 Diesel Conversion & AC Install

I searched and searched the forum for this A/C install and found nothing, can anyone provide us with the direct link?
#125627 - in reply to #94241
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Posted 6/30/2008 2:08 PM
stevegsmith
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Date registered: Apr 2006
Location: SF Bay Area, CA USA
Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99
Posts: 1301
1000
RE: 460 Diesel Conversion & AC Install

Here are a couple more pics of the York compressor bracket (that came stock on some mercedes sedans) modified for the Sanden compressor.
If I can find more info or pics, I'll repost.








(new.bracket.JPG)



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Attachments new.bracket.JPG (43KB - 19 downloads)
#125633 - in reply to #94241
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Posted 6/30/2008 2:23 PM
stevegsmith
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Date registered: Apr 2006
Location: SF Bay Area, CA USA
Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99
Posts: 1301
1000
RE: 460 Diesel Conversion & AC Install

more pics.

The main issue was getting the turbo intake, alternator bracket, and thermo housing and outlets to work together.

I sourced the thermo housing (I think from a 200D) but don't have those part numbers in front of me at the moment. I'll dig them up if anyone is interested.

One flaw in the design though (currently dealing with) is the belt tensioner pulley. The york style pulley is probably fine but the bracket has to be reinforced where the adjustment arm attaches to the bracket. My bracket cracked at this location due to the vibration and demand on the pulley from the long belt....I suspect.

I'm thinking a pulley tensioner with the threaded rod type adjustment would be better than the swing arm type. I haven't had a chance yet to source parts so I haven't completed the fix. If anyone has a pulley part suggestion, I'd love to hear it.

Steve






(DSCN0377.JPG)



(DSC00018.JPG)



(DSC00020.JPG)



(DSC00022.JPG)



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Attachments DSCN0377.JPG (176KB - 15 downloads)
Attachments DSC00018.JPG (59KB - 12 downloads)
Attachments DSC00020.JPG (59KB - 12 downloads)
Attachments DSC00022.JPG (61KB - 16 downloads)
#125636 - in reply to #94241
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Posted 6/30/2008 2:43 PM
genghis03
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Date registered: Sep 2007
Location: Left Coast, USA
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Posts: 250
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RE: 460 Diesel Conversion & AC Install

stevegsmith - 6/30/2008 11:23 AM I sourced the thermo housing (I think from a 200D) but don't have those part numbers in front of me at the moment. I'll dig them up if anyone is interested.

I'm interested Steve!  I have this setup with the Sanden compressor in my 460, but soon will be swapping the motor for a 617A turbo diesel, and I've been thinking long and hard about how to keep my A/C (need it in the 100 degree heat out here!).

Thanks, 

 

#125638 - in reply to #125636
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Posted 6/30/2008 7:31 PM
Fernando BR



Date registered: Jan 2007
Location: Brasil
Vehicle(s): G500/05 300GE/91 300GD/80
1000
RE: 460 Diesel Conversion & AC Install

Nice system Steve !!!!!


Did you use the original system inside? Liked a lot the belt invertion cranckshaft/water pump/ alternator ...to compressor /crackshaft / water pump. The Ac / crack shaft to alternator crack shaft ! Are you using a large belt instead the double one?



Edited by Fernando BR 6/30/2008 8:35 PM




(AC1.png)



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Attachments AC1.png (38KB - 9 downloads)
#125658 - in reply to #94241
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Posted 7/1/2008 12:37 AM
dai
Expert




Date registered: Apr 2006
Location: Oregon USA
Vehicle(s): 300GD 300TD BMW R100RS Landini 80F
Posts: 2110
2000
Re: 460 Diesel Conversion & AC Install

That bracket was used in 220 and 240 diesels that had the York A/C compressors. It makes R+R of the wasserpumper a time consuming job but if you must have A/C in the G this is the way to do it.

The thermostat cover is also from a 200/220 diesel and probably the 240D. The 617 thermostat cover will not work with the A/C bracket.

It might be possible to use the alternator threaded rod from an older non A/C alternator setup from an early sedan to tension the A/C pulley. The A/C equiped motor alternators used a cheesy tension setup that will not work. The only problem I have had with those early idler/tension pulleys from the old motors is the failure of the bearing in the pulley. They handled the long belt routing well. The fastener to hold the tension adjustment had to be really tight. Again this is relating to the 220D and early non 123 chassis 240D sedans.

-Dai





Edited by dai 7/1/2008 12:58 AM
#125679 - in reply to #125638
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Posted 7/1/2008 12:48 AM
stevegsmith
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Date registered: Apr 2006
Location: SF Bay Area, CA USA
Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99
Posts: 1301
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RE: 460 Diesel Conversion & AC Install

Fernando BR - 6/30/2008 4:31 PM

Nice system Steve !!!!!


Did you use the original system inside? Liked a lot the belt invertion cranckshaft/water pump/ alternator ...to compressor /crackshaft / water pump. The Ac / crack shaft to alternator crack shaft ! Are you using a large belt instead the double one?



That aftermarket unit is very much like the one I used to have. I removed it and installed a stock unit I removed from a 280GE. Lots of mods involved but much cleaner in the cab.

I'm using a single v-belt.

I will track down part numbers tonight and try to post tomorrow.


#125680 - in reply to #125658
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Posted 7/1/2008 8:23 PM
stevegsmith
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Date registered: Apr 2006
Location: SF Bay Area, CA USA
Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99
Posts: 1301
1000
RE: 460 Diesel Conversion & AC Install

Okay, so here's some more info. I don't have part numbers for the hoses, so in that regard, you're on your own. My upper radiator hose is pieced together using two uppers from different engines and a steel pipe for the splice. I might have a part number buried somewhere for the lower hose and will post it if found.

The thermostat housing is from a 68-73 220D, 615 engine.
Upper piece 6152030074
Lower piece 1152000115

The water pump housing is the one that came with my 83 vintage 617 A from an 300SD.
6172010501

Good luck.






Attachments
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Attachments turbo_transplant_thermo_housing.pdf (89KB - 48 downloads)
#125734 - in reply to #94241
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Posted 4/16/2011 3:51 PM
elevatorbernie
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Date registered: Aug 2006
Location: Vancouver B.C. Canada
Vehicle(s): 1989 280GE
Posts: 1347
1000
RE: 460 Diesel Conversion & AC Install

Old post, but I have a few questions about this AC setup, maybe Steve Smith can chime in. Shown in this picture, is that part the lower hose is connected to...the water pump housing or another piece? thanks Bernie



(new.bracket.JPG)



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Attachments new.bracket.JPG (86KB - 7 downloads)
#188259 - in reply to #125734
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Posted 4/17/2011 6:31 AM
Boy G
Expert


Date registered: Feb 2007
Location: Bushveld, South Africa
Vehicle(s): Diesel G's: 617A and 602
Posts: 1683
1000
RE: 460 Diesel Conversion & AC Install

I know your truck is probably lhd and therefore this mount is irrelevant but this was how I got mine sorted.

I did a drawing of this bracket if anyone wants a copy.



(PA200035.JPG)



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Attachments PA200035.JPG (141KB - 8 downloads)
#188280 - in reply to #94241
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Posted 4/18/2011 7:52 AM
Jonathan Joseph
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Date registered: Oct 2006
Location: Charleston, South Carolina
Vehicle(s): 2004 G55
Posts: 1538
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RE: 460 Diesel Conversion & AC Install

Bernie
That's a separate piece. See the hose on the upper end of it? That little hose connects to the water pump or block I can't remember now. I had to replace that little hose and that little aluminum fitting comes off with it. I guess it's just a splitter to allow that heater hose to connect.

Jonathan
#188309 - in reply to #94241
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Posted 4/19/2011 2:21 AM
elevatorbernie
Expert




Date registered: Aug 2006
Location: Vancouver B.C. Canada
Vehicle(s): 1989 280GE
Posts: 1347
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RE: 460 Diesel Conversion & AC Install

Jonathan Joseph - 4/18/2011 4:52 AM

Bernie
That's a separate piece. See the hose on the upper end of it? That little hose connects to the water pump or block I can't remember now. I had to replace that little hose and that little aluminum fitting comes off with it. I guess it's just a splitter to allow that heater hose to connect.

Jonathan
That's what I thought too, however Steve S posted this for me over on cgw. It is part of the water pump housing. The one I have on my turbo engine doesn't have the pipe I've marked with an arrow, it only has a small pipe to the heater. This water pump housing has to be used with the type of t-stat housing he's using or there's no place to hook up the inlet hose from the rad. Bernie



(Untitled.png)



(IMGP3337.JPG)



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Attachments Untitled.png (150KB - 5 downloads)
Attachments IMGP3337.JPG (102KB - 5 downloads)
#188372 - in reply to #188309
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Posted 4/19/2011 2:44 AM
elevatorbernie
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Date registered: Aug 2006
Location: Vancouver B.C. Canada
Vehicle(s): 1989 280GE
Posts: 1347
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RE: 460 Diesel Conversion & AC Install

Boy G - 4/17/2011 3:31 AM

I know your truck is probably lhd and therefore this mount is irrelevant but this was how I got mine sorted.

I did a drawing of this bracket if anyone wants a copy.
Thanks Andrew, you sent me a copy awhile back, great job on the design and drawing, but my G is LHD and the steering box is in the way. However the drawing is still helpful and the design might be adapted (made in reverse) for use on the right side of the engine where the alt is located. The alt could be moved up top RH side. thanks again bernie
#188373 - in reply to #188280
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Posted 4/19/2011 7:28 PM
stevegsmith
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Date registered: Apr 2006
Location: SF Bay Area, CA USA
Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99
Posts: 1301
1000
RE: 460 Diesel Conversion & AC Install

Hey Bernie. How's this?




(617A_mod_thermo.JPG)



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Attachments 617A_mod_thermo.JPG (159KB - 6 downloads)
#188417 - in reply to #94241
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Posted 4/20/2011 2:57 AM
elevatorbernie
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Date registered: Aug 2006
Location: Vancouver B.C. Canada
Vehicle(s): 1989 280GE
Posts: 1347
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RE: 460 Diesel Conversion & AC Install

stevegsmith - 4/19/2011 4:28 PM

Hey Bernie. How's this?
Thanks Steve, that pic really clears up the mystery, were you able to find the # for the pump housing?
#188437 - in reply to #188417
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Posted 4/20/2011 12:21 PM
stevegsmith
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Date registered: Apr 2006
Location: SF Bay Area, CA USA
Vehicle(s): 82 300GD WVO, 06 Jeep Lib CRD B99
Posts: 1301
1000
RE: 460 Diesel Conversion & AC Install

elevatorbernie - 4/19/2011 11:57 PM

stevegsmith - 4/19/2011 4:28 PM

Hey Bernie. How's this?
Thanks Steve, that pic really clears up the mystery, were you able to find the # for the pump housing?

Not yet Bernie. I was kinda hoping Mark J would ID it. He's good at that stuff. I'll keep poking around.
#188456 - in reply to #188437
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