PeachParts Mercedes-Benz Forum - View Single Post - 606 G-Wagon Swap

duxthe1 · #1 08-03-2018, 08:31 PM

Have a customer with a 300GD that had a 603 Non-turbo with significant compression issues. Decided to do a 606 turbodiesel swap. Dropped the engine in today and took a couple pics.

So Far:

Swapped for a mechanical 603 turbo injection pump and used the original throttle bracket and fabbed a couple linkages. One hole through the webbing in the intake manifold to run the linkage down and another to have access to the aneroid adjustment. Manual trans and no cruise control so it was fairly straight forward. Just a few bends in the linkages and levers to clear everything.

Used mostly 603 fuel lines and filter but used the 606 lift pump and thermostat in the head. Head was drilled and tapped by the front outlet to install the fan switch. This was the most nerve wrecking part. The bung is already cast but you only get one shot to drill and tap it right. Used the 603 oil filter housing. The oil cooler lines needed some careful creative bending but they eventually fit.

Original 603 oil pan was swapped to get the RPM sensor mount in the bellhousing but found it would have been needed to clear the left motor mount as well. With the RPM sensor in the oil pan the original engine control module can idle the turbodiesel injection pump without any modification. Original glow plug harness had 606 connectors soldered on and was routed to clear the mechanical throttle linkage.

Still to do:

Fabricate a downpipe to connect to original exhaust at first joint.
Fabricate intercooler mount and ductwork. This is the most challenging part left. There is room, but not in excess.
Fab and install a positive pressure wastegate.
Fab heater hose and reservoir connection.