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  #1  
Old 05-17-2009, 05:04 PM
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replacing a 603 with 5 cylinder

Has anybody ever replaced a 603 with the 5 cylinder? It's in a 91 350sd.
Thanks.
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  #2  
Old 05-17-2009, 05:28 PM
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I believe someone here has done this swap, and it wasn't as straightforward as they originally thought it would be.

If your 350 has "bent" the dust, why not look for a 603.96x that has a cracked cylinder head? You can use your head and the good 3 liter lower end to make a very reliable motor. Or look into the cylinder sleeves and pistons available for the .97x. Though they are spendy...

-J
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1991 350SDL. 230,000 miles (new motor @ 150,000).

2012 Passat TDI. 95,000 miles. More space, power, and fuel economy than the Benz
2004 Touareg V10 TDI. 150,000 miles. One of 450.
1999 Jetta TDI. 310,000 miles.
1992 Jetta ECOdiesel. 156,000 miles. 1 of 48. Sold.
1991 Jetta ECOdiesel. 430,000 miles. 1 of 700. Sold to VeeDubTDI, totaled in front of our house
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  #3  
Old 05-17-2009, 07:56 PM
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Replacing a 603 with a 617

Yes it can be done. I suppose it depends on how much you want to do and how technically competant you are. (High degree of skill for this job.)

Recently, W. Roy Hunter (see below) and I have been working on just such a change. However, in our process we started with a body shell (no engine / trans / some of the interior) and were moving stuff from an 85 617 SD to a 603 SD. There are a number of issues you should be aware of:

Complete drive train removal and replacement takes a long time. So far about 3 weeks of part time work with 2 people.

We took everything from the engine to the entire rear end of the 617 SD and transplanted it to the 603 SD. In doing that the 603 SD 3 piece drive shaft was not able to be used. We removed the 300 SD driveshaft bracket and transplanted / secured it into the 603 SD. Then ground down the 2 other brackets. (rust proofing as we went along)

The rear dif is off-set and thus cannot be used with the 617 SD drive shaft / trans combination. The rear axle assembly including springs and support arms is a bolt in. But this is difficult to do.

The motor mounts are the same in both vehicles. I think the trans mounts are the same as well. (not sure, check with W. Hunter)

The engine shock on the driver's side uses a different bracket placement on the 603 SD vs the 617 300SD. (the 617 engine shock will need a new bracket welded onto the 603 SD engine cross member in the 617 SD location)

Electrical (starting ciruits) and vacuum systems are different and will have to be sorted out (a work in progress) You have to remember that the engine /trans was already out so we could not verify / save all the original connections. It's going to take some detective work.

The fore and aft false bulk head / heat shield on the passenger side can be disposed of. In its place you will need to install the heater pipe. The pipe uses the same holes as the false bulk head did.

Working on a Texas (southern) car is a lot easier than working on a rusty northern car (car we were transplanting to was from Texas).

Vacuum out all the mulch under the battery tray and brake booster or you may have a fire in your future.

The car is running, but not all electrical / vacuum are hooked up. The starting circuit is still a mystery. Roy had to jumper it to get it started.

Call / PM WHunter to get the real low-down and where he is at.
W. (Roy) Hunter (forum member & moderator and forum TECHNICAL SUPPORT Roy Roy@PeachParts.com See the Fastlane left panel for a phone number.
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  #4  
Old 05-17-2009, 08:00 PM
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603 to 617

Of course if you have the transmission, I'm not exactly sure if the 617 will bolt up to the 603 transmission. As stated in the prior note, the motor mount positions are OK, 1 engine shock is not and the electrical / vacuum stuff is a question mark.

Roy may know about this.
W. (Roy) Hunter (forum member & moderator and forum TECHNICAL SUPPORT Roy Roy@PeachParts.com See the Fastlane left panel for a phone number.)
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  #5  
Old 05-17-2009, 08:48 PM
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602 5cyl might be easier !
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  #6  
Old 05-17-2009, 09:07 PM
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Quote:
Originally Posted by oldiesel View Post
602 5cyl might be easier !
I agree. The OM602/603 engines are nearly identical, to the extent that the factory published one manual for both of them.
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  #7  
Old 05-17-2009, 09:11 PM
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why??

WHy not get a 603 from an SDL or 87 300D. Less work and much nicer rider
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  #8  
Old 05-17-2009, 11:57 PM
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"Vacuum out all the mulch under the battery tray and brake booster or you may have a fire in your future."

While this is important I think you will find the 603 equipped body doesn't have the blower resistor pack there. You're going to have to do some tricky wiring if you want to keep the updated climate control system because it is looking for an RPM signal from the AC compressor.

-J
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1991 350SDL. 230,000 miles (new motor @ 150,000).

2012 Passat TDI. 95,000 miles. More space, power, and fuel economy than the Benz
2004 Touareg V10 TDI. 150,000 miles. One of 450.
1999 Jetta TDI. 310,000 miles.
1992 Jetta ECOdiesel. 156,000 miles. 1 of 48. Sold.
1991 Jetta ECOdiesel. 430,000 miles. 1 of 700. Sold to VeeDubTDI, totaled in front of our house
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  #9  
Old 05-18-2009, 11:49 PM
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I agree with the above, go 3.0L 603 instead. The 5-cyl 602 turbo engine is probably harder to find (be sure you don't get an '87 unless the head has been updated) and will not load the springs properly, but otherwise should be only minor issues.
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  #10  
Old 05-19-2009, 12:46 PM
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Answer.

FYI: 300SD transplanted to 350SD body
FYI: 300SD transplanted to 350SD body




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  #11  
Old 05-19-2009, 11:13 PM
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Thanks for all the info. The reason I had posted the question was that I picked up an 91 350sd with the 603 and the guy lost oil pressure and shut it down pretty quick. But, to turn the engine with a pull handle is real hard. He had his Indy tell him he thought it was the main/rod bearings.
I've got the 5 cylinder in a 83 300sd that the body isn't great on but the engine is great. I was bouncing around what my best approach might be.
Thanks for the info.
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