New to diesels and putting an OM617 in a Jeep

[gregman_1]

Hey guys/gals. New to diesels here so I've been doing a TON of research. I've watched practically all of Mercedes Source's videos, read all of ForcedInduction's writeups on Mercedes Forum on how to tune the IP and wastegate. Still going very conservatively until I feel like I know what I'm doing.

A little about me: I'm a piston aircraft mechanic, and I've been fixing stuff my whole life. I've built motorcycle, car and aircraft engines and I know what goes on inside a machine. I find these old mechanical diesels very satisfying to work on since everything is mechanical and works with a fair amount of common sense. I am no stranger to engine internals, turbos, welding, ETC.

About the swap recipient vehicle: A 1990 Jeep Wrangler I've owned for the better part of 20 years. It has the old TBI 2.5 four cylinder in it, which has the dubious distinction of having the dumbest fuel injection system on Earth. There is no onboard diagnostics AT ALL, and troubleshooting can only be done by taking a live readout of the sensors while the engine is running, using a piece of dealer-only equipment that doesn't exist anymore. I'm tired of fooling with it. I will be reusing my AX-5 manual transmission with the help of a Koch swap kit.

About the donor vehicle: A 1985 300D I purchased from a Facebook group (of all places) for $500. OM617.952, MW pump, KKK turbo, 280k miles. It runs great, but I will be doing some tune up projects before it's pulled from the donor car, and then some more projects while it's on the engine stand. I need to troubleshoot/fix the vacuum shut off, replace the turbo oil inlet gasket, replace the glow plugs (has a weak one) and adjust the valves. While it's on the stand I'll clean a bunch of stuff up and probably rebuild the turbo, then once it's in the Jeep and operating correctly, I'll probably turn the pump/wastegate up for a bit more power.

I'll probably pester the crap out of you guys for help as I go along, since this is my first diesel project and my first Benz. Let me know if there are any common pitfalls for new guys or if you just plain think I'm an idiot. Thanks!

[mach4]

There are numerous build threads on engine swaps on PP. My own, a 617 into an SL chassis is well documented. There are also threads on swaps into a Studebaker PU, a Toyota PU, a s10 PU, a Ranger and on the list goes. In the end it's a very straightforward, though not always easy, process involving various levels of engineering, fabrication, trial and error and tenacity. The steps are - make it fit; hook up all the systems; make it pretty.

As I understand it, the biggest problem with a Jeep is clearance between the front axle and the engine sump.

Read through the build threads and you'll identify the areas of concern and various solutions to the issues. In my own build it took well over a year with 90% of the time being research and contemplation of solutions. Now that everything is sorted, I could re-do the swap in a couple weekends.

If you proceed, start a build thread and share your process with LOTS of pictures. THe more info you provide the more responses and ideas you'll get.

Oh, and one other thing - make sure your proposed swap is legal where you live. Every state is different and the requirements can vary from onerous to non-existent.

It's been done before - https://m.youtube.com/watch?v=T3oeMgjZ6xY

Good luck.

[southofantarctica]

I've done it in a CJ7, which is pretty much identical body wise to your YJ. Like Mach said, the biggest issues will be the front axle. I installed a lift to get the clearance, but the other option is to cut and splice the oil pan for more clearance. I left the transmission in the stock location so that I did not have to get new drive shafts.

I used all the existing ignition components, with the addition of the Mercedes glow plug harness. I ran the front half of the Mercedes vacuum line and ran it into the Jeep brake booster. I do not run a vacuum expansion tank but still have the motor turn off via vacuum when the key is off.

I am still fighting high temperatures when at speed above 55mph. I haven't had time to work on it in quite some time to figure it out. Power does seems to be lower than hoped, but I do think that some tuning adjustments would clear most of that up.

[gregman_1]

Originally Posted by mach4

As I understand it, the biggest problem with a Jeep is clearance between the front axle and the engine sump.

Yeah I've read aplenty on the sump clearance issues. Luckily, my Jeep already has about 3.5" of suspension lift (I have seen YJs with this amount of lift and stock OM617 sumps) and 2" of body lift, and I'll probably put the motor mounts together with the engine a bit higher than stock (which will also help out my rear driveline angles.)

Originally Posted by mach4

If you proceed, start a build thread and share your process with LOTS of pictures. THe more info you provide the more responses and ideas you'll get.

Yep, I've been planning on doing a full You Tube series, as there is really just not a lot of easily locatable videos on the actual swap process. I want to help people who try this swap in the future, as well as get some ideas from people who have already done it.

Originally Posted by mach4

Oh, and one other thing - make sure your proposed swap is legal where you live. Every state is different and the requirements can vary from onerous to non-existent.

Luckily, I live in rural Georgia where there are no emissions requirements or inspections, so I do not expect it to be a problem. I do believe Georgia might have a "law" on the books stating that the donor engine must be newer than the chassis, but I have never ever ever heard of that being enforced, and I have spent a lot of time around people who have swapped all kinds of things.

[gregman_1]

Originally Posted by southofantarctica

I've done it in a CJ7, which is pretty much identical body wise to your YJ. Like Mach said, the biggest issues will be the front axle. I installed a lift to get the clearance, but the other option is to cut and splice the oil pan for more clearance. I left the transmission in the stock location so that I did not have to get new drive shafts.

I used all the existing ignition components, with the addition of the Mercedes glow plug harness. I ran the front half of the Mercedes vacuum line and ran it into the Jeep brake booster. I do not run a vacuum expansion tank but still have the motor turn off via vacuum when the key is off.

I am still fighting high temperatures when at speed above 55mph. I haven't had time to work on it in quite some time to figure it out. Power does seems to be lower than hoped, but I do think that some tuning adjustments would clear most of that up.

That sounds like a neat set up for sure. As far as the high temperatures, you did retain the M-B oil cooler, right? I understand that these diesels do not like to run without them. I will probably be putting a three row aluminum radiator in mine as well, since the 26-year-old brass two row radiator that's in there is starting to weep again and the radiator shop said they couldn't rebuild it again after the last time.

[dude99]

read all of ForcedInduction's writeups on Mercedes Forum on how to tune the IP

I would be carful with this, there is a growing movement on superturbodiesel that discredits his methods and offers a better one. It is downloadable on that site as a pdf only. I would pop your head in over there and ask a couple questions before you touch your pump.

Other than that, I await pictures Everyone loves a build thread

[bricktron]

if you want to keep reading, the book "bosch diesel engine management" may be the best reference on the injection pumps.

[gregman_1]

Originally Posted by dude99

I would be carful with this, there is a growing movement on superturbodiesel that discredits his methods and offers a better one. It is downloadable on that site as a pdf only. I would pop your head in over there and ask a couple questions before you touch your pump.

Other than that, I await pictures Everyone loves a build thread

Been awaiting my activation email from STD for a few days, looking forward to that info.

[gregman_1]

Originally Posted by bricktron

if you want to keep reading, the book "bosch diesel engine management" may be the best reference on the injection pumps.

I will check that out for sure!

[resto108]

Didn't think parts were available for the KKK turbos....

[Rogviler]

Originally Posted by resto108

Didn't think parts were available for the KKK turbos....

Yep, you just gotta know where to look. There's a great shop that sells kits that I'm sure someone will post a link to before I can remember the name of it.

EDIT: G-pop Shop is the one I was thinking of.

-Rog

[OM617YOTA]

Welcome to the forum!

Sounds like a fun swap. Though mine is more on the redneck side, I enjoy it quite a bit.

[t walgamuth]

I'm the guy with the with the 39 Studebaker coupe express with the 617 and five speed manual. I'll keep an eye on your project thread and offer any help I can.

Good luck!

[panZZer]

Originally Posted by gregman_1

Hey guys/gals. New to diesels here so I've been doing a TON of research. I've watched practically all of Mercedes Source's videos, read all of ForcedInduction's writeups on Mercedes Forum on how to tune the IP and wastegate. Still going very conservatively until I feel like I know what I'm doing.

A little about me: I'm a piston aircraft mechanic, and I've been fixing stuff my whole life. I've built motorcycle, car and aircraft engines and I know what goes on inside a machine. I find these old mechanical diesels very satisfying to work on since everything is mechanical and works with a fair amount of common sense. I am no stranger to engine internals, turbos, welding, ETC.

About the swap recipient vehicle: A 1990 Jeep Wrangler I've owned for the better part of 20 years. It has the old TBI 2.5 four cylinder in it, which has the dubious distinction of having the dumbest fuel injection system on Earth. There is no onboard diagnostics AT ALL, and troubleshooting can only be done by taking a live readout of the sensors while the engine is running, using a piece of dealer-only equipment that doesn't exist anymore. I'm tired of fooling with it. I will be reusing my AX-5 manual transmission with the help of a Koch swap kit.

About the donor vehicle: A 1985 300D I purchased from a Facebook group (of all places) for $500. OM617.952, MW pump, KKK turbo, 280k miles. It runs great, but I will be doing some tune up projects before it's pulled from the donor car, and then some more projects while it's on the engine stand. I need to troubleshoot/fix the vacuum shut off, replace the turbo oil inlet gasket, replace the glow plugs (has a weak one) and adjust the valves. While it's on the stand I'll clean a bunch of stuff up and probably rebuild the turbo, then once it's in the Jeep and operating correctly, I'll probably turn the pump/wastegate up for a bit more power.

I'll probably pester the crap out of you guys for help as I go along, since this is my first diesel project and my first Benz. Let me know if there are any common pitfalls for new guys or if you just plain think I'm an idiot. Thanks!

I had the 86 comanche, first yr of that throttle body injection,
the truck got ripped off when I was vacationing in Ca
80 hp and a 4 speed was _sOOOO _fun to drive across the country good times, but I wish I still had it.

[panZZer]

Originally Posted by mach4

There are numerous build threads on engine swaps on PP. My own, a 617 into an SL chassis is well documented. There are also threads on swaps into a Studebaker PU, a Toyota PU, a s10 PU, a Ranger and on the list goes. In the end it's a very straightforward, though not always easy, process involving various levels of engineering, fabrication, trial and error and tenacity. The steps are - make it fit; hook up all the systems; make it pretty.

As I understand it, the biggest problem with a Jeep is clearance between the front axle and the engine sump.

Read through the build threads and you'll identify the areas of concern and various solutions to the issues. In my own build it took well over a year with 90% of the time being research and contemplation of solutions. Now that everything is sorted, I could re-do the swap in a couple weekends.

If you proceed, start a build thread and share your process with LOTS of pictures. THe more info you provide the more responses and ideas you'll get.

Oh, and one other thing - make sure your proposed swap is legal where you live. Every state is different and the requirements can vary from onerous to non-existent.

It's been done before - https://m.youtube.com/watch?v=T3oeMgjZ6xY

Good luck.

ide say the biggest problem is a good 5 speed and Tcase adaptable to the ole clatter trap