'89 Wrangler YJ Mercedes Diesel Swap OM 617 - My First Swap - Page 3 - Jeep Wrangler Forum

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Old 05-16-2013, 07:29 AM   #61
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Quote:
Originally Posted by mattchatman View Post
Exciting! Let me know how that tech adapter works for you! I finally got my computer working so it's time to get some factory gauges working instead of GPS speedometers and old Mercedes gauges in the floorboard.
Ill let you know how it goes, if I get off work with daylight left, I am gonna try and get it installed today. I highly recommend getting a boost controller and egt gauge. runs much better at 14 psi.
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Old 05-20-2013, 10:01 AM   #62
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The girlfriend was in NY for the weekend, so I spent pretty much the entire weekend working on the Jeep.

I got the Dakota Digital tach adapter installed, very simple to install. I am a bit dissapointed in that I emailed Dakota Digital and they told me the tach adapter would work with the hall effect sensor. Well, it did not. The tach was bouncing all over the place with the hall effect, and no where near accurate. No big deal really, just means I had to run it off the W-terminal on my new alternator (stock alt for the OM617 does not have a W-terminal unless you add it yourself). I wanted to use the hell effect because that would mean no calibration necessary. Hooked up to the w-terminal, I have it reading about 600 RPM at idle, which is not correct, but I ordered a laser photo tach reader for $16 off Amazon, should get here today and then I can calibrate the tach. I am considering printing a new gauge face label for the tach though, since the stock gas tach has a much wider RPM range that is not needed with the OM617.

I also did some major re-wiring which I will add pics of tomorrow. Finished moving the battery from the engine compartment to the bestop rough rider storage box on the passenger rear wheel well, abandoned my idea of using a fuse box in the engine bay, and just re-did all of the wiring. It came out really nice I think, it is by far the cleanest wiring job I have EVER done. With all the space I gained by removing the battery tray, I ran the intake into that area.

Previously, I had the oil cooler mounted on the driver side front fender well in the engine compartment. I decided to attach it to the connecting support rod that goes from the firewall to the grill, right in between the brake booster and the grill. This gets it off the fender and lets it cool on all sides. It also looks a lot better.

Put in a lot of work on the interior wiring and installed some red indicator lights on the dash, one for the glow plugs and one for the EGT warning light. I also bought a 12v buzzer alarm, this will wire in with the EGT warning light. The digital EGT gauge has an adjustable warning level, you set what temp you want it to go off at, and it will trigger the light and buzzer. That way if you hit 1200 deg or so on the EGT, you will know it and not destroy the engine. I want to get an oil pressure switch and wire it up to the vacuum switch that shuts off the engine as well, that way if something goes and I lose oil pressure, it will cut the engine before it destroys itself.

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Old 05-28-2013, 11:50 PM   #63
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So, all-in, what was your final cost on the swap?
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Old 05-29-2013, 10:05 AM   #64
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Spent around 2000 in parts total, but I sold the old engine and parts for a total of 1150. So only really cost me less than a grand...
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Old 05-30-2013, 09:22 AM   #65
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Awesome build man
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Old 10-07-2013, 12:27 AM   #66
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just wondering were you got you new monark nozles?
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Old 10-08-2013, 11:30 AM   #67
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Rick

You mentioned you replaced the rear axle with a Ford 8.8 with 3.73 gears. Did you replace the front axle gears with 3.73's?
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Old 10-08-2013, 03:27 PM   #68
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I read this entire post with fascination. What a great build!
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Old 10-08-2013, 06:20 PM   #69
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outstanding

Read this thread twice now! It was out standing, like to see what you could have done with a space shuttle down here at NASA! LOL
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Old 10-10-2013, 10:51 PM   #70
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Best to you on this diesel project. A fellow at the Ocean City event had a diesel conversion ( 4 cyl. Cummins I was told), that got a lot of attention. I have high regard for you guys that can pull this off.
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Old 07-08-2015, 06:29 PM   #71
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what type of tranny did you use?
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Old 07-12-2015, 10:54 AM   #72
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He used the stock auto. with an adapter plate.
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Old 09-18-2015, 03:23 AM   #73
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Well I was reminiscing reading back through this as the Jeep sits, possibly totaled, after someone decided they would t-bone me on my way to work a couple weeks ago. Between the Jeep and my back, its really stinks.

But to answer some questions, I got the Monark nozzles from mercedessource.com and they were worth every penny...

I retained the original 3-speed auto. Jeep only has around 50k miles and the tranny was in excellent shape. I went ahead and replaced seals, filter, fluid and the like when I did the swap since it was all pulled apart. New transmission mounts, torque arms, and bushings as well. All said and done, not a drop of tranny fluid on the ground and a ride so smooth I couldn't even beleive it. And yes, I did buy the adapter, got it from mercedesdiesel4x4.com. GREAT quality, no issues with fitment, it worked great.

I have seen a couple swaps with the 4bt. They have more hp, thats for sure, but they dont get the fuel economy that the OM617 gets, and they shake like all get out. I think someone told me you have to have a separate vacuum pump as well in order to operate the brake booster....
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Old 09-18-2015, 03:54 AM   #74
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O and as far as axles go, I installed an 8.8 with 3.73 gears, limited slip, and disk brakes. Rebuilt with new rotors, calpers, pads, etc... I don't have much time to go offroading, but I never even need my 4wd in the snow or mud with the limited slip. I used to spin out on the ramp trying to pull my boat out of the water with the 4.2L and the stock D35 rear, but with the diesel and the 8.8 rear, I literally just put it in drive and it rolls right up the ramp without even giving it throttle.

I would say this, I had a hard time finding good info on gearing for this motor and the tf999/rh32 with 32-33" tires, so I did some calculations and went with the 3.73. In retrospect, these diesels love being opened up, and I probably could have increased my fuel economy even more (was getting around 22city/28hwy with 3.73s) to over 30mpg hwy and gained some low end acceleration had I gone with an 8.8 with 4.10 gears. 4.56 or 4.88 would probably be perfection, but then you are getting into regearing since you will be hard pressed to find a factory Ford 8.8 rear with gearing >4.10. I was going to stick with the 3.73s though, because I bought a vgt turbo from a Mercedes Sprinter van that came with a Hella electronic actuated controller. I even had all the parts pulled together, arduino to control with most of the code written (but untested obviously), two diesel flow meters to get an exact read on fuel consumption, pressure sensor to feed input, and a crap ton of other stuff. These engines have a ton of unlocked power, I was going to try and move the power and torque curves by using the vgt to build boost (maybe 2 psi) at idle and increase the fuel flow so that it has all it needs the instant you step on the gas. Lots of info over on superturbodiesel.com on others that have done similar...
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Old 10-03-2015, 08:12 PM   #75
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What a shame.
Hope you and the Jeep recover soon.
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Old 10-22-2015, 05:05 PM   #76
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I'm finally getting around to starting my own OM617 swap, and your thread was pretty handy. Mine is going to be part of a complete ground-up rebuild of my '90 YJ (SRS, SOA, 0-2" springs, frame repair/blast/paint, body lift, etc) and I finally decided to use a 700R4 instead of my old AX15. Transfer case will either be the stock NP231 (with SYE) or a Dana 300 I picked up a few years back. Axles will be Dana 60 front (Ford or GM depending on which TC) and 14-bolt rear, both narrowed, with 35-37" tires. I'm not sure if I'll adapt a Painless CJ harness or just build my own. I picked up a running engine in March, I believe, and it's been sitting in a friend's garage since then. It'll probably be next summer at the earliest before I finish, but I blew the original 4.2l over 3 years ago so I'm not rushing anything. I hope both you and the Jeep recover, or that they at least sell it back to you for cheap so you can salvage whatever you can.
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Old 03-22-2016, 12:43 AM   #77
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What an awesome engine swap. I'm currently tearing down a '87 yj and was planning on putting in a sbc. Now I may have something else to consider. I do have a question. On the 8.8 swap did you ever have any issues with widening the pilot hole and using the explorer spring perches? I know that you said you had 4 inch lift springs did you run them sua?
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Old 06-22-2016, 09:26 PM   #78
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I know this is an old thread but...

Quote:
Originally Posted by snowbrd84 View Post
Well I was reminiscing reading back through this as the Jeep sits, possibly totaled, after someone decided they would t-bone me on my way to work a couple weeks ago. Between the Jeep and my back, its really stinks.
Oh man! When I read that my jaw dropped! The same kind of thing happened to me about 6 months ago so I feel your pain.

Loved the thread though. Tons of great info and enough inspiration to make me start looking for a donor. I figure what better time to do an engine swap then when I have my heep down to the frame! I hope you get your jeep back on the road soon.
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Old 10-09-2016, 09:43 PM   #79
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i have been into this thread like crazy and im doing the swap now. i need some help!!! most of what im needing is pics of what all i need and how its wired up. how to get the throtel linkage hooked up and can i by pass the overboost thing form the banjo bolt on the intake to the alda? most of all i need pics pics pics plz.
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Old 10-09-2016, 09:46 PM   #80
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yes there are lots of miss spellings sorry fingers are in pain tonight

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