Diesel Bombers - Another Mercedes OM617 into a Wrangler

Diesel Bombers (https://www.dieselbombers.com/)

- Diesel Engine Conversions (https://www.dieselbombers.com/diesel-engine-conversions/)

- - Another Mercedes OM617 into a Wrangler (https://www.dieselbombers.com/diesel-engine-conversions/31815-another-mercedes-om617-into-wrangler.html)

hulkgreen

08-29-2009 07:27 PM

Another Mercedes OM617 into a Wrangler

A special thanks goes to a fellow member of this forum for inspiration and advice!!! THANK YOU SO MUCH VLADO ; YOU ARE A GREAT FRIEND !!

But , here is my Mercedes om617 into my 1994 wrangler ( not quite complete ; but getting there !! )

The adapter from JEEP flywheel to Mercedes crank with provision for Jeep Pilot Bushing!!

http://my.project-jk.com/data/2017/m...o_JEEP_001.JPG

http://my.project-jk.com/data/2017/m...o_JEEP_005.JPG

The engine to Bellhousing adapter ( which the machinist flipped over before milling and offset everything so my Dakota Bell would not work ) so I used the AX-15 Bell housing so as not to scrap the WHOLE PIECE and start over !!

http://my.project-jk.com/data/2017/m...o_JEEP_006.JPG

http://my.project-jk.com/data/2017/m...o_JEEP_009.JPG

Both adapters bolted to engine !!

http://my.project-jk.com/data/2017/m...o_JEEP_015.JPG
And the tolerances are quite close but the 1/4 inch won't hurt anything !!

http://my.project-jk.com/data/2017/m...o_JEEP_020.JPG

And the stock Jeeps clutch is now in place !!

http://my.project-jk.com/data/2017/m...o_JEEP_023.JPG

---AutoMerged DoublePost---

And the project continues !!!

Underside view !!

http://my.project-jk.com/data/2017/m...o_JEEP_019.JPG

Underside with the jeep starter in place and the dreaded part was clearancing the cooling fins about 1/8 of an inch ( I hated it but, it had to be done !!)

http://my.project-jk.com/data/2017/m...o_JEEP_026.JPG

http://my.project-jk.com/data/2017/m...o_JEEP_014.JPG

Some of the final mock ups before she goes into the Chassis ( hopefully tomorrow ) to have the motor mounts welded to the frame !!

http://my.project-jk.com/data/2017/m...o_JEEP_031.JPG

http://my.project-jk.com/data/2017/m...o_JEEP_030.JPG

Dr. Evil

08-29-2009 07:31 PM

too cool - great pics

hulkgreen

08-29-2009 07:41 PM

With the AX-15 it was a very tight fit for the starter and I was really afraid of the heat but ; It looks like I was worried for nothing there seems to be plenty of space !!

http://my.project-jk.com/data/2017/m...o_JEEP_029.JPG

and here is the tolerance of the starter AFTER CLEARANCING THE COOLING FINS !!

http://my.project-jk.com/data/2017/m...o_JEEP_024.JPG

But ; by doing this ...... you can stop at any parts store and purchase an off the shelf starter and replace it in their parking lot in NO TIME !!!!

vlado

09-02-2009 05:03 PM

:oops3:hate to tell you"I TOLD YOU SO" dakota bell wont work
second picture from bottom up that shows your bell housing and starter.if you moved that starter few inches up and cut out about 1 inch from bell housing it would have cleared your engine cooling fins.that is what i did and that is reason my bell housing looks different than yours.still it is good thread

hulkgreen

09-02-2009 09:46 PM

Quote:

Originally Posted by vlado (Post 388409)

I unfortunately will never find out !! The machinist flipped the piece over and that offset everything the wrong way !! I did not feel like scrapping a $50 dollar piece of aluminum so I worked with what I was given !! I probably would have had to use the Dakota starter as well but GOD only knows NOW !! :5::5::5:

And after seeing how little space is left next to the battery and everything else for the exhaust ...IT is REALLY TIGHT FIT !!! .... I really wish I had tried !!!!

hulkgreen

09-04-2009 09:27 AM

This is the tight fit for the exhaust !!

http://my.project-jk.com/data/2028/m...gether_001.JPG

hulkgreen

09-10-2009 09:14 PM

If you are interested in following along I have set up a link to flickr to make it easier to post pics.... :U::c:

Flickr: hulkgreen's Photostream

hulkgreen

09-15-2009 03:38 PM

Decided on a home-made .. cold air induction ..... while waiting for the right intercooler to come along at the right price .... I could run the piping under the battery and up the windshield for a snorkel effect !! :rocking:

http://farm4.static.flickr.com/3480/...0235055a1c.jpg

http://farm4.static.flickr.com/3437/...7ce59f13e0.jpg

hulkgreen

09-25-2009 07:52 AM

My friends....

IT IS ALIVE !!! :yeah:

Got it started last nite using the mercedes electronics ; Unfortunately it had a fuel leak so could only let it idle for less than 10 minutes !! :argh: Of , course it was 10 pm so I must go spend my day searching down the leak !!

GOtta GO !!! I am so stoked ; since it was not much louder than a common rail cummins and that was thru the straight pipe exhaust since I have not connected it to my stock JEEP muffler yet !! :U:

hulkgreen

10-01-2009 01:02 PM

Found the fuel leak .... THe 24 year old fuel return lines had dry rotted !!! :argh: They still had " made in germany " printed on them !!

Took it to town to top off with Diesel and when I got home I noticed a heavy oil leak !! It appeared to be coming from the Injection Pump .....the gasket has failed ( also 24 years old :argh:.... and had to order it from the Mercedes Dealer.....!! I had to pull the oil filter housing to get the Injection Pump off and now I have to get the FILTER to BLOCK gasket ( and it is available thru the Mercedes Dealer also .... SO no big deal !!! :yeah:

I also ordered ( Monday ) some 1 1/4 lift shackles for front and rear to get the oil pan off the front differential !! Should have everything back together and back on the road by the weekend !! :ok1::ok1:

vlado

10-01-2009 04:22 PM

glad to hear you have everything under control. your shackels will give you only 5/8 of actual lift.that wont help you much in my opinion.maybe you should have ordered 2 in shackles to get 1 in of extra clearence,or make your own set. just my 2 cents:ok1:

Benzer1

10-01-2009 08:58 PM

Adapter & Bushing

5 Attachment(s)

Hi Guys,
Here are some pics of the adapter plate and bushing I made. I cut a ring out of the flexplate off the gasser, it was already drilled for the torque converter pattern. I welded 8mm bolts to it in the pattern of the Benz flexplate. Then I milled out an aluminum adapter to line up the snout of the torque converter with the Benz flexplate. It goes together nice. I still need to cut the aluminum bushing to length after I figure out how far it goes into the crank. Now I am going to put the torque converter back on the trans and measure the bellhousing pattern for the engine to trans plate. Just an update...

John

hulkgreen

10-06-2009 11:46 AM

Quote:

Originally Posted by vlado (Post 403347)

Correct !!! The lift shackles were just enough to get it off the diff !! I am gonna make some spacers to fit inbetween the motor mounts and the rubber engine mounts about 1 " thick and this may help with drive line angles later on when I really get serious about going off road !!!! :U:

---AutoMerged DoublePost---

Quote:

Originally Posted by Benzer1 (Post 403496)

Dam John ..... That looks like ALOT of work just to be able to use the Auto trans !!!! But ; It seems to be coming along nicely !!!

I never have been a big fan of an auto trans ..... It may have been worth it to convert to manual trans and not had so many headaches !!!!

Between me and Vlado we could have helped ya with the engine to ( manual trans ) stuff !! :c::c:

AND IF YOU EVER HAVE AN OIL LEAK THAT IS COMING FROM THE INJECTION PUMP WHERE IT MEETS THE BLOCK .... 1st MAKE SURE YOU DON'T HAVE AN OIL PAN BOLT THAT IS MISSING ..... 2nd GO BUY SOME GASKET MATERIAL AND MAKE IT YOURSELF ; CAUSE IT IS NOT AVAILABLE THRU THE DEALER UNLESS YOU ARE BUYING THE WHOLE INJECTION PUMP ASSEMBLY !!!

hulkgreen

10-10-2009 01:51 PM

Decided to get the Rough Country 2.5 inch spring lift !! Will install it on Monday/ Tuesday !! I have 2 adapter plates sold and I need concentrate on getting the machine work done ; so I can get them delivered before I go in for my back surgery !! :ok1: I want these pieces taken care of before my surgery ; so I have one less thing to stress over !! :yeah::yeah:

Benzer1

10-20-2009 08:25 PM

Update

I set the engine down into the engine bay tonight. Do you think I could install a drop pitman arm to lower the steering linkages instead of lifting the vehicle? I really like the stock ride height. I am almost done with the plate that goes between the engine and trans. Once I bolt the engine and trans together, I will slide them in to measure for the motor mounts. I removed the grill and radiator support to aid in fitting the engine/trans combo.

John

Benzer1

10-23-2009 07:23 AM

Adapter Plate

2 Attachment(s)

Here is a pic of the finished plate and the notched trans bellhousing. Tomorrow I am going to bolt the engine and trans together.

josephy

10-27-2009 08:43 AM

Hey there hulgreen are you recovering from your surgery good? I was wondering if you could email me on the status of your engine mounts and also some more details about the adapter plate.

thanks
vr4thrust71@hotmail.com

hulkgreen

11-02-2009 02:09 PM

Quote:

Originally Posted by josephy (Post 418841)

Hey josephy,

if you check out post # 7 of this thread there is a link to my flickr photostream ; which should answer your questions about the engine mounts and I need clarification on what details you are wanting with the adapter plate ???

If you are inquireing about purchasing ..... that has to be done thru Private message !! :ok1:

beeser

11-06-2009 11:51 PM

Quote:

Originally Posted by hulkgreen (Post 405866)

Yeah, except, automatics are SO much better for off-road. Besides, if the car wasn't already equipped with a manny tranny, you have to put in the clutch/brake pedals, clutch mechinism, etc.

I will soon be doing my own conversion: '86 XJ Wagoneer (basically a fancy Cherokee), '83 OM617A with Aisin automatic from a later, 4.0 litre XJ. I really like, and know, the Torqueflites (which my Jeep already has), but I want the overdrive the later XJ's had.

Stay tuned. Photos are forthcoming....

Mark

Benzer1

11-08-2009 09:37 PM

Update

I finished the motor mounts, fuel lines, and put the transfer case back in. I enlarged the hole in the fuel tank filler for diesel. Still need to order a drop pitman arm and get a 4.0 radiator. I think I have room for the factory clutch fan if I use the 4.0 radiator. I will take some pics soon as I get a little further. Now for the wiring, hoses, etc.....

John

beeser

11-10-2009 10:06 PM

Hey Benzer1,

Are you using the 6-cylinder MB diesel in your XJ, or the old 5-cylinder iron head? I see you have an '87 300SDL listed for "My Diesel" in your profile. That car had the OM603.

Mark

Benzer1

11-11-2009 07:20 AM

Quote:

Originally Posted by beeser (Post 429201)

Hey Benzer1,

Are you using the 6-cylinder MB diesel in your XJ, or the old 5-cylinder iron head? I see you have an '87 300SDL listed for "My Diesel" in your profile. That car had the OM603.

Mark

Hi Mark,
The engine is the OM617 (5 cyl) turbo. The engine came from a 1982 300 SD.

John

wfoote

11-12-2009 07:36 PM

Hulkgreen, I am in the preliminary stages of putting an om617 into a late model cherokee... By preliminary I mean that I have everything needed to complete the conversion except fabbed up motor mounts (1993 Jeep cherokee 4x4 w/ax-15, 1985 MB 300SD, 4x4labs conversion kit)...

Anyway my questions are, how are you going work out your throttle control? Are you just going to fab up a bracket to utilize the original jeep cable?

Also, for power steering did you just braze the jeep hoses to the MB pump, or buy some kind of adapter fittings?

And lastly, for operating the jeep vacuum stuff (mainly brake booster) did you just plumb everything straight into the MB vacuum pump, or did you utilize all the matter of restrictors and check valves like what was factory installed on your MB donor vehicle? And if not, did directly plumbing everything affect the MB engine shut off operation?

Thanks in advance

hulkgreen

11-15-2009 12:32 PM

Quote:

Originally Posted by wfoote (Post 430502)

wow ; you mean 4x4labs FINALLY finished their kit ??? It was what over 3 years in the making ???

And what did you have to pay for their kit ???? I would think they would be able to answer all your questions ???? BUT ; if you look at my flickr acct which there is a link in my signature ( you may have to go to post # 18 to see my signature ) not only are your questions answered but there are pictures of HOW to do it !! :rock:

josephy

11-16-2009 07:32 AM

adapter plate

Hi there Hulgreen I'd like to chat with you about your adapter plate can you send me your email please at vr4thrust71@hotmail.com

thanks

dealwithit

12-02-2009 03:33 AM

your adapter plate looks awfully thin for aluminum? how thick is that?

hulkgreen

12-07-2009 04:14 PM

Quote:

Originally Posted by dealwithit (Post 443208)

your adapter plate looks awfully thin for aluminum? how thick is that?

It is 5/16 inch thick !!! That is the necessary thickness to make sure the clutch works properly !!!

dealwithit

12-07-2009 06:58 PM

ah ok gotcha, any worries about strength tho? i would have gone with steel if thickness was an issue. could have also got some metal milled off the face of the bellhousing if a thicker piece was needed.

Benzer1

12-07-2009 10:10 PM

adapter plate

My plate is only 1/4" aluminum, but with an automatic it should be OK. I would have went thicker, but it's already tight in front. I guess time will tell.

John

dealwithit

12-07-2009 10:40 PM

yikes, thats pretty thin for aluminum. if you have to pull the motor for any reason in the next while i would seriously think about tracing it out onto some steel and use that for your plate. i would really hate to see it bend when you go down a bumpy road...

FTE	12-07-2009 10:57 PM

Just wondering if Beeser got started on his project? Looks like he&I are doing the same set up

snowgun2

08-02-2013 08:01 PM

Does anyone have the dimensions for the AX15 or NV3550 bellhousing? I am looking to make my own adapter and this would help allot! If you have a CAD that would be amazing!
:tu:

OM617XJ

09-08-2016 09:15 PM

Quote:

Originally Posted by hulkgreen (Post 386515)

who made the flywheel adaptator? size/depth?

Codyyj

02-01-2017 10:37 PM

Starter issues

I can't get my start to catch the flywheel on the Diesel motor. I grind a lot of and can see a gap between engine and starter. New starter. Please help :(

All times are GMT -5. The time now is 09:33 AM.