I know there are 1,000 posts on this subject, but I can not find an actual breakdown of what is needed to do this swap.

I have an 89 Wrangler YJ with a 4.2 and Auto Trans w/ 4" lift.

I just ordered an OM617 out of an 85 300SD complete with all accessories and turbo.

Here is my understanding on the parts I will need:

1) OM617 Engine Complete (Ordered)
2) Transmission Adapter Kit (Not yet ordered, mercedesdiesel4x4.com??)
3) Motor Mounts (Not yet ordered, mercedesdiesel4x4.com??)
4) Exhaust parts to connect route to an connect to existing cat converter.

Ok thats all I can really think of, but that cant be it can it?

Will I need additional parts or fab work to connect the throttle linkage?

Will I need to make adapters to connect the power steering pump to the steering box?


In my mind this is an incredibly easy swap since the hard work is done being able to buy the trans adapter and the motor mounts. I am planning on taking pictures and doing a writeup of the entire process from pulling the existing motor all the way to finishing the swap. I am stoked at the thought of the simplicity of these Mercedes Diesels. Any help is much appreciated.

 

dude dont put a cat on that thing!

 

depending on where he lives, he mightn't be able to register/tag the vehicle without a cat on it. In Nevada, they used to "ding" my early-98 (Tiny) until I reinstalled one..... Here in South Texas (Nueces County), not an issue, though, for example.

 

there are two ways to make ps hose. the first is use the MB high pressure hose and the stock jeep hose, take to hydualic shop to have joined with crimp fitting.

second way is to use both metal tubes MB and jeep. Buy hydraulic hose to length with JIC swivel ends, use two JIC plugs drilled for Metal tubes and braze in. then connect two fittings. throttle is not real hard i have some pics.

 

As far as the cat goes, its a magnaflow high flow cat and its basically brand new so I will probably just leave it on...

Once the engine arrives next week I will take the high pressure hose in with the stock jeep hose and have them joined.

One big question is, should I pull the trans when I pull the old motor and then mate the trans with the OM617 outside the rig before putting it all in at once? Or would it be OK to just pull the engine and leave the trans in???

 

Are you taking the core support off? Also could you trace out a template of the trans and flywheel adapter befor you put it on? I'm doing the same swap with a jeep Cherokee 5 speed and I'd like to build the adapter

 

What is the core support?

You would need a detailed cad drawing of the adapter as it is definitely a machined piece...

I am pretty much stuck at the moment because all of the external vacuum system components were missing from the motor. I am trying to figure out the bare minimum vacuum requirements...

 

Radiator core support, the metal between the headlights that the hood latches to.

 

Any guesses on how long a cat would last behind a diesel before getting clogged?

 

Ditch the d35 rear axle if you havent already.