While the engine is out
 

I have the engine (617) out of my 300SD but it's not going into the truck until the spring. I'm planning on pulling the intake and cleaning it out, I'll probably accidentally misplace the EGR at the same time, and it'll be getting an aftercooler as well. I need to replace basically all the oil return o-rings, the oil pan gasket, and the vacuum pump would probably be a good thing to do as well.
The engine has over 200k on it, so timing chain as well? I know it needs a valve adjustment and cam cover gasket, and it was nailing a little when cold so the timing chain probably has some stretch.
I'm intending to relocate the oil filter too, with a remote dual filter system. Does anyone have a diagram showing oil flow out the holes on the block?

Is there anything else that is made much easier by having the engine out? Any tips or tricks?

Rear crankshaft oil seal, practically speaking can't be done except with the engine out. You'll have the oil pan off anyway!

Be a good time to check the freeze plugs in the block, maybe no problem in some places but if you're in the rust belt they can be pretty rusted from winter salt. Easy to do with the engine on a stand and a bear to do with the engine installed!

Regarding the relocation of the oil filter/housing, do a search of "MercedesRover" you'll find this gentleman has already designed and manufactured an adapter plate for the 61X engine block. I suspect that plate can be the basis for your application, then sone hoses and whatever filter head you prefer! Good Luck!

My suggestion is that while the 617 is out, you should stick a small block Chevy in the car/truck whatever it is, and use the 617, as a boat anchor...:D

Why would I want to be like every other wife-beater wearing redneck stuffing a small block v8 into a mini truck? I want to be a little different. I have a buzz cut instead of a mullet. I have an Akita/lab cross instead of a chocolate lab. I have a selection of foreign military rifles instead of a single variable choke 12gauge.
Besides, I wanted a diesel.

Than my next suggestion, if you want Diesel power, real Diesel power, stick a Powerstroke in the thing. Out of a Ford. The Benz mill will surely come up short of your expectations. Unless you've got some serious gears. The 77 horsepower, or whatever it is, won't get your truck out of it's own way.

Adding an aftercooler denotes a turbocharged engine, an OM617.951 in this case. That's 123hp out of the box, should be 135-140 with the higher boost and pump mods allowed by the addition of the aftercooler, not 77hp.
The truck is a Courier, can you find a way to fit a PSD into a Courier? I'm elbow deep in an EJ swap on my GL turbowagon, I don't need something else that needs 40miles of wiring right now either.


Question- Why in the hell am I sitting here justifying my swap to you? You're some anonymous guy who's waltzing in here to tell me how I'm doing it wrong. I know a bit more than you about all ranges of vehicles, guaranteed. I'll do my thing, you be an irritation somewhere else.

welder, set of piston rings & rod & main bearing shells would be sensible. You could even get the valves reseated if you wanted. oil pumps are cheap.

Better than something from a Ferd would be a 12 Valve Cummins. What truck is this going in? The SD isn't exactly light so he should go faster that the original luxurious MBZ besides, it's his truck.

:clap::clap::clap::clap::clap::clap::clap::clap:

Most forums make me feel this way!
I love the comradeship on this forum, and you guys are great... But sometimes I'll avoid forums all together for this very reason.

Barvo 4x4 you said it! Don't let anyone get under your skin. I love your idea and the Benz engine will make a great little truck. I wish you the best of luck.

You wish him the best of luck...? So do I. He's most likely going to need all the luck he can get.... It isn't the install that I have a problem with. It's the result. Nothing to do with his mechanical ability, nothing to do with the particular vehicle. It's just got a lot to do with the lack of sack in the engine to begin with. It's going to move like a 1500 lb. pedal car. It's like putting a 4 cylinder, from a Chevette, into a '71 Monte Carlo.

So? These engines are also a pleasure to work on due to their simplicity, I don't think anybody here is going to be going out racing. I don't see the point in discouraging anyone from utilizing a diesel mercedes engine on a diesel mercedes forum...

Should I start another thread and let you use this one to trash on the engine I am using in the forum for the engine I am using? You very obviously do not know anything about this engine, so what are you trying to contribute?
Seriously, you are not a help right now and I'd rather you didn't post in this thread anymore.

As far as power, the basic architecture of this engine will handle 250-300hp with proper pump and turbo mods. I'm not going radical just yet, for now I've just turned up the pump a bit and it'll have a free flowing exhaust and a decent air filter.
In time, I will get and rebuilt another pump for it with larger elements, and weld up a new stainless header to work with a variable turbo off a Dodge Cummins engine, along with a nice shiny new stainless intake manifold so I can use a front mount aftercooler without having a mile of tubing and 140º bends between the turbo and intake.

DUDE! I think the picture in your signature suits you pretty well!

He's putting an OM617 turbo from an SD into a Courier - you know, the Mazda-based mini-truck?

The first gen Couriers only weighed around 2500 pounds - over a thousand pounds less than the SD the engine is coming out of. Plus the Courier 4-popper made about 75 HP and 92 ft/lbs torque - compared to 125HP and 180 ft/lbs torque for the OM617 turbo. Even the numbers on the second gen Couriers show them to be way lighter than the SD and have engines with significantly less HP and torque than the OM617 turbo

As for the PowerStroke idea, the only way you're getting a 'stroke in a Courier is to chop up and shorten the chassis the 'stroke came in, and then perch the Courier body on top of it. Basically take a useful full-sized truck and make it a mini-monster truck whose oddity is its only redeeming feature. A pretty hair-brained idea if you ask me.

Sorry if I seem to be coming down on you too hard, but you're obviously offering your "authoritative advise" on this swap without even having looked at the specs for the engines and vehicles involved.

So until you've done a few swaps like this yourself, how about keeping your advice to yourself and sit back to listen to the folks around here who have done some serious wrench and fab work. You might learn something and avoid looking like a CLOWN...

Hey guys, 4x4 asked for suggestions of work he could do on a 617 while it was out. How about we all behave like grown men and concentrate on helpful advice. We don't need to have a contest to see who can Pee the highest on the urinal !!!