Im thinking about using the wagon as a donor vehicle and swap everything over. Id really like to keep the early dash and instrument cluster. Would there be any issues with the speed signal not going through the cluster? And what other issues might i run into, such as the alternator wiring, if i keep the early style cluster and dash? Thanks
Im running a t5 trans in the wagon currently so i could run a speedo cable to the old cluster to see my speed, so im not too worried about that as long as it runs the way it does in the wagon.
I did the Lh2.4 swap about 2-3 years ago on my 1975 242 with a 1990 244 donor for the engine, FI system and wiring and a 1985 245 donor for the M46, dash and interior pieces. Its a totally doable job to take on, I would make sure you have wiring diagrams for both cars.
This is my write up on the transplant:
http://forums.turbobricks.com/showthread.php?t=324743
These are some of the major items I encountered:
- Installed a 1984 instrument cluster as the M46 has the speedo cable, and the cruise control pickup on the back of the speedo. Your 1980 speedo may have that cut out as CC was an option at that point. I prefer the 1981 and new dashes as they have slots for 52mm gauges which the earlier dashes don't have.
- You'll need to rewire the instrument cluster as power is delivered through a different place on the electronic speedometer units (1986 and newer), and possibly for the warning, indicator, and idiot lights.
- Replaced out the 242 wiring from the front seats forward, only wiring retained was the leads to the rear lighting, fuel pumps, gas gauge, rear window defroster and speakers. This was a sizeable effort, for me it made things easier and cleaner than trying to integrate the 70s wiring with the 90s wiring especially with the FI system. With this approach had to change out things like the headlight switch as they are different.
-The wagon wiring into a sedan will have other differences for the rear hatch such as third brake wiring (which will cause issues with the bulb out sensor if its missing) rear wiper, and locking mechanism.
- There may be some differences with the 92 donor having ABS.
- The fuel pump/filter will need to be taken from the donor or you will need to retrofit the lines coming off the firewall mounted fuel filter on the 1980 Kjet car.
- The back of the ignition switch will need to be swapped out. These were different on the 1990-93 240s, believe to kill the headlights when starting the car.
- With the Lh2.4 wiring harness, you may need to either cut a hole or swap out the passenger firewall plate from the donor.