Chevy S10 ZR2 4x4 Mercedes OM617 Diesel Swap
 

I have been wanting to do a diesel swap into a small truck for a while now. I have a 90mile round trip to work, and I like to hunt/fish ect. I needed something that I could do both in while getting decent MPG with the possible use of WVO or Biodiesel.

Bought a Toyota 4x4 a couple years ago...it got 16MPG. Had a Ford Ranger...it got 17MPG, My F250 gets 14mpg, so I couldnt justify either of the smaller trucks. I have to have the F250 since I pull lots of equipment..not work related.

I always have some type of beater car to drive to work as long as they get good MPG I dont care what they look like (and are cheap!). Right now I have a 1983 300d that I take to work. It gets 22-24MPG, has lots of blowby. I am hoping with the Chevy 5 speed I can get close to 30MPG in my ZR2.

The head gaskets in the Toyota went out about the time I was going to sell it..., so I bought a 1982 Mercedes 300SD to swap into the Toyota. The 300SD came with 93,000 original miles. The guys son got Tboned and the car was toast... 400$ and it was mine. Still ran like a champ, and I drove it a couple times before I pulled the motor. After some measuring I decided that the Toyota engine compartment was too tight for the swap, so I sold the Toyota with bad head gaskets.

I found a 1995 Chevy S10 ZR2 4x4 with a 5 speed manual on Craigslist that had a bad motor. I gave the guy 600 bucks plus a trade for some crap I had and it was mine.

I have been reading EVERY post about any type of OM617 swap that I could find. So I began my swap. So far I have pulled both engines. I am going to put a 2" body lift on, and am waiting for my longer bolts to arrive for the body lift. Today I ordered my aluminum plate .5" thick to make my adapter plate.

Any tips would be helpfull if you have done this swap. I read on one post from one of the "vettes" that they had to use a 85 and down flywheel? Never gave a reason. I am planning on having mine drilled to fit unless there would be problems.

I am planning on using a Chevy starter that they use in racing applications. It can be clocked to different positions for propper fit.

Any input, suggestions or tips?

I am also keeping track of $$$ spent on the swap. So far:
600 ZR2 Truck
400 Mercedes 300SD donor car
48 Nylon body lift blocks
30 Body lift bolts
80 .500 17"x17" 6061 aluminum plate

check with Mercedes diesel 4x4 the can help an you might want to put a solid axle under the front

After inspecting my flywheel a bit it appears to be external balanced. I guess that explains the need for the 85 and older flywheel since they are internal (neutral)balanced. I am also going to need to have a spacer machined to space the flywheel from the crank.