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  #1  
Old 12-13-2012, 08:42 AM
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250 HP using OM606.962 with OM603 IP?

Hello everyone. I've been a long time lurker, but I am a first time poster. My name is Henry, and I am currently located near Chicago, Illinois.


As a possibility, I am looking to swap in a Mercedes diesel into my Jeep Wrangler.
I was thinking of using an OM606.962 engine and putting the mechanical injection pump on it from the OM603. I am trying to eliminate the majority of the electrical system and want to keep it as simple as possible.

If I swap out the 6mm elements from the 606 IP to the 603 IP and upgrade the turbo, would I be able to make 250 horsepower at the crankshaft?
If possible, what size turbo would I need? What other things would I have to do?
What kind of torque could I expect to see? 400-450 ft. lbs (542-610 N m)?

I am trying to keep it a relatively simple build without having to send out an IP to Finland.

Any help would be greatly appreciated.
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  #2  
Old 12-13-2012, 10:21 AM
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Not having the IP built overseas will limit your potential. If you happen to find a shop stateside that will swap elements for you, more power to you.

I think your best bet is to adjust the full load on your 603 pump. That will help a fair amount, getting you to maybe 200 hp...

Turbo wise, you can role with a hx35 and be pretty happy. With an element swap its probably smarted to look into a hx40.
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  #3  
Old 12-13-2012, 10:32 AM
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Try and find an IP from a 3.5L 603 as it has 6mm elements. Like mentioned above the most you can do before sending it overseas is adjust the full load and put a bigger turbo and an intercooler.

disregard this info, I researched it and the 3.5L pump does not have 6mm elementes the 606 electronic IP does so if you can swap the 6mm elements to the 603 pump and get it recalibrated you'll be good.

Last edited by TheDon; 12-17-2012 at 04:59 PM.
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  #4  
Old 12-13-2012, 10:44 AM
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Quote:
Originally Posted by TheDon View Post
Try and find an IP from a 3.5L 603 as it has 6mm elements. Like mentioned above the most you can do before sending it overseas is adjust the full load and put a bigger turbo and an intercooler.
With an IP from a 3.5L 603, would it be better to go with the HX35 turbo or the HX40?

I figure 200 HP with 300 ft. lbs. of torque is what could be expected if the IP was dialed in correctly?
I just didn't know if there was a little bit more that could be gained by performing a few other tweaks.
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  #5  
Old 12-13-2012, 12:19 PM
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Turbos come down to you and how you like their maps. Also don't forget you'll need a custom exhaust and exhaust manifold for the holdsets
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  #6  
Old 12-14-2012, 08:08 PM
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An HX40 is far too big for 200HP. In my opinion, HY35 is best for quicker response, HX35 for more exhaust flow.
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  #7  
Old 12-17-2012, 07:26 AM
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This is all great information. Thanks to everyone who has taken the time to respond. I really appreciate it.

Once I get more and more into this project, I'm sure I will have a few more questions.
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  #8  
Old 12-17-2012, 01:43 PM
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Speaking of more questions...

This is a little off topic, but out of curiousity, if I wanted to keep the electronics and stock IP, would it be a moderately easy swap, at least when compared to say an OM648?

I've tried researching the OM648 and information seems limited. Should that be an engine worth considering, or should I just stick with the 606?

I know some of these engines are wiring nightmares, but as long as I am able to get my hands on the schematics of the wiring diagram, I feel pretty comfortable in being able to figure it all out to fit my specific application.

I'm assuming at this point that it would also just make more sense in retaining the OEM transmission as well?
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  #9  
Old 12-17-2012, 03:56 PM
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You can disregard the last post; I was able to find a decent amount of information regarding the OM648.

Based on what I have been able to find, I will stick with the initial plan of the 606 engine and 603 IP. Initial thoughts also have me leaning towards an HY35 turbo.

Is there anything else I need to consider? EGR maybe?

When I get the donor engine, what electronic components do I need to retain to make all of this work? Would I be able to just use a generic wiring harness and adapt it to fit this application?
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  #10  
Old 12-17-2012, 05:02 PM
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Disregard my post about the 3.5L pump.

you will essentially need the engine harness from the 603. I am doing the 606 swap into my w124 and I am going to get another harness for the engine and glow plugs. For the glow plugs I need to change the plug on the 606 harness so it can interface with the 603 type of glow plug relay. There is no "generic wiring harness" for this swap.

other than that since you're swapping it into a jeep there will be different connections needed for coolant temp sensor and etc.

I believe you might need the EGR computer from a 603 powered car for idle control, I'm unsure of this but someone should be able to help.
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  #11  
Old 12-17-2012, 10:50 PM
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Couldn't I just do an EGR block-off/bypass? I'm assuming that when I pull the engine from the donor, it would be worthwhile to also pull the wiring harness as well?

I've been melting my brain trying to read the various 606 builds. Taking notes as I go along...hopefully I can get a good list going.

I just want to make sure I get all of the needed parts off of the donor vehicle(s).
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  #12  
Old 12-18-2012, 10:12 AM
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For the turbos I fully endorse a VNT setup. Yes it's more complicated, but being able to choose between a gradual 8psi on the highway or a near-instant 18psi is great.
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  #13  
Old 12-20-2012, 12:47 PM
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Quote:
Originally Posted by uzrnaim View Post
Couldn't I just do an EGR block-off/bypass? I'm assuming that when I pull the engine from the donor, it would be worthwhile to also pull the wiring harness as well?

I've been melting my brain trying to read the various 606 builds. Taking notes as I go along...hopefully I can get a good list going.

I just want to make sure I get all of the needed parts off of the donor vehicle(s).
I'm in the same boat as you are for my 606 build. I need an injection pump and figure out how to make the linkages work and then I'll be good to go
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