OM617 Swap into 97 Jeep Wrangler
 

This is my first diesel swap, EVER. I expect to get alot of headaches and frustration... so i hope i get alot of help from you guys :D

my plan was to gather all the necessary stuff for the swap before starting

So far....

Engine (82k miles original), Turbo :rocking:, Fuel Pump, Original Engine Harness (Fully Intact), MB Power steering pump, MB A/C Compressor, MB Glow Plug Relay, A-MB208 Adapter Kit (from Mercedesdiesel4x4), MB113 Exhaust Kit (also from mercedesdiesel4x4)

What i need to get....
Need to convert my gas tank to a diesel tank (must flush and clean) for the conversion i was thinking of using the Fuel Pump conversion for the jdjeepstore, or should i use my current fuel lines? <------------- Room for Suggestions

Jeff Daniels Jeep Customization


I need to fabricate motor mounts because apparently the ones they have at mercedesdiesel4x4 dont fit my model without "Major modification" :argh:

if anyone knows anywhere else where i could buy this, it would help alot, or atleast a picture of what the fabrication of my mount should look like... Maybe measurements... mhmmm...:argh:

A-MB106 Motor Mounts

Alternator Preferably one that fits on the MB alternator bracket, i read that the 60v alternators blow... and that i should aim for a 150v...:humm:


If im missing any items please feel free to post under i appreciate all the help i can get, though i am a novice, im very passionate about this project and my jeep :D

I can also use help on any diagrams of wiring the engine harness to my current jeep harness:humm:

Look foward to help and criticism!

The Work place

Some pics of the jeep

the dismantling begins

Is the motor a 617 or a 617A? will make a big difference if you are looking to make some extra power.

just getting started on the same swap. Just finished pulling everything out of my wrangler last night. Got to get rid of the old V8 and auto transmission so I got room to work in the garage. How's your project coming along?

Let me know if you guys need any help with the TJ electronics. I know them top to bottom. There's no reason to rip out the stock cluster, it's actually pretty easy!

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That'd be sweet!

I'm doing the same swap but I'm stuck on the motor mounts. If anyone could post pictures of their mounts to help give me an idea that would be awesome. (1997 jeep wrangler 4 cylinder)

Sorry guys havent been on in a long time real busy, even fell behind on my project >.>

its coming along nicely, got my engine in the car believe its a 617a

as for the mounts its pretty tough to say, i cut off the old mounts and reused them, some people reuse the MB motormounts but i made my own, ive seen some use old chevy rocker mounts. but i think reusing the old mounts is the best cost efficient way to go.

Working on converting my gas tank and i should be done with my build, just gotta do the a/c later on, but i just want it running with the top off :P

anybody know how to wire up the wires so that the cluster works. I got my motor mounted and but I'm just going to wire up a toggle switch for the glow plugs and a push button for the starter. but I was wondering if anyone knew how to wire up the alternator so it charges the battery properly?

Do you still have your PCM connected? The PCM regulates the alternator and runs the gauges. At the moment there isn't any way to make the gauges work without it (working on it), but the alternator can be ran with an external regulator from an 80's Dodge.

Yes I do have it still hooked up as far as I know. But I'm not sure which weird I need to spice or if there was maybe a one wire alternater that would work with the Mercedes bracket.

The crank sensor needs to be hooked up, and it needs a signal from the cam sensor at startup before the PCM will turn on the cluster or start charging.

The easiest way to accomplish this is to hook up the crank sensor, either in stock location or fabricate something if not available, then connect the cam sensor signal wire into the crank sensor. Yours should be like mine, and have 3 wires to each sensor. If so, each one has a power, ground, and signal wire returning to the PCM. The power and ground should be the same colors on both sensors, so just take the one that's different on the cam sensor, and tie it into the one that's different on the crank sensor. Make sure not to hook the power or ground in by mistake. A reman PCM is $300 IIRC...

If I do the Saab alternator upgrade do I still need the external regulator?

I'm not familiar with the Saab alternator. Is it internally regulated?

It is internally regulated, so no regulator required. On another note and sorry to hijack the thread, what do I do about all of the injector wires, the MAP sensor and the throttle position sensor, and the O2 sensors?

I just depinned mine, and removed those harnesses. Some share power and ground with other things, so you'll need to separate them at the junctions if you do that. Some things can be handy to keep though, like the manifold temp sensor. I have mine tapped into my charge tube after the intercooler, and access it via an OBD bluetooth adapter and the Android Torque Pro app.

Depinned, you mean at the PCM? I guess the bigger question is will the jeep run without those things being handled? Like maybe the wires just cut?

Yeah I was wondering. My plan was to set the glow plugs up on a toggle switch and then set starter up with a starter relay with a push button start. Then go to like auto zone and buy one of the three Guage pods that have oil pressure, coolant temp, and battery voltage. Then getting rid of almost all of the wires. But my only problem would be is how can I get the alternator to charge the battery?


Also if anyone is struggling with motor mounts I can upload a few pictures of mine. I wasn't able to find any images anywhere online so if anyone want to see let me know and I'll post them.

I'm doing the same with the glow plugs. I haven't as yet got things to the stage of alternator hook ups. You might want to check the post by Evenglass and his Cherokee/OM617 swap. He did a spectacular job not only with the install, but also showing what-when-why-how he did it with photos, and he did show some alternator info. I have been borrowing shamelessly from his post for my ideas to get things done.

I was wondering if you could post a link to it. I am new to these forms and I have no idea how to look up his post.
Thank you

https://www.dieselbombers.com/diesel...ld-thread.html

Try this. I am pretty tech challenged, so I hope this gets you where you are going. If not, look at page 2 of the diesel conversions forum for an OM617 jeep Cherokee conversion the guy's handle is Evenglass

atrussell: Check here for the alternator info. How to identify your GM Internally Regulated Alternator | American Autowire

Question, are you using the stock trans and tranfercase axles and so on?

I am trying to find a good cheap way of swapping in a diesel into my XJ. I am not trying to hi-jack your thread. I am just looking to figure out what you did and how you did it.

FWIW: I have gone through 2 Ford starter relays with my swap. The second stuck open and killed my DieHard Platinum Battery. I am now installing a GM glow plug relay, let's see if it can handle the constant amperage. I have the SAAB alternator in my FJ80 OM617 swap, and all is good. It was a nice $25 110a upgrade from the junkyard. Internally regulated, so a cinch to wire.

OM617 Swap into 2001 Jeep Wrangler