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Old 08-19-2013, 09:21 PM   #1
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Jeep Diesel Swap

Hey,

So I figure this is as good a place as any to start another engine swap thread. I have not been working on this a lot and the project has had to be put on hold for various times.

I had a 1997 TJ with the 2.5L gaser and a bad transmission. Even when the trans was running right I never got more than 16 mpg. It was gutless too. So I read about a guy who swapped a diesel into a CJ and figured...sounds good.

I wanted a om617, but was lured into buying a om602 because it was newer, had been rebuilt recently and was a good deal. I should have went with the om617 since more people have done it and there is less hassle.

Here is the engine prior to being removed:



I was kind of surprised how much hoses and wiring they had for a basic engine. As you can see from the date, it's been a while.

I removed the ac and replaced the front and rear main seals along with alot of other items. It took a while to clear all the sludge.

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Old 08-19-2013, 09:26 PM   #2
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So then I pulled the Tj motor and ax5 trans. I picked up an ax15 trans and rebuilt the TC case to match the AX15.

I did have to have the adapter plate and a lot of parts custom made. Local machine shops that are still in business are really busy. So it was hurry up and wait.

I had the motor mounts made and welded in place. I modified the belly plate and trans mount. Pulled the fuel tank and removed the in place pump and used a pickup tube. I installed return lines and a breather valve.

Here is the motor in it's new home. After several installations and removals.


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Old 08-19-2013, 09:28 PM   #3
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So, I had to get a new radiator and battery and a tone of other smaller stuff. I was able to sell alot of the old benz parts and saved a lot of wiring and plumbing.

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Old 08-19-2013, 09:30 PM   #4
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I kept the fan and added the ben's dual electric fans up front. I am using the benz power steering mated to the Jeep.

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Old 08-19-2013, 09:32 PM   #5
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After messing around with the firewall, I raised the body and relocated the oil filter. It's final position is still open for debate.

I had to fabricate the adapter plate on the engine block leading to the spin-on oil filter adapter.
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Old 08-19-2013, 09:33 PM   #6
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Awesome!
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Old 08-19-2013, 09:35 PM   #7
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What was amazing is that after sitting idle for two years, the motor started relatively easily. I primed up to the secondary fuel filter and then cranked for a while. Then hit the glow plugs and it started. Like it had just stopped 2 minutes ago. It ran like a Swiss watch.

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Old 08-19-2013, 09:37 PM   #8
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Excellent! But I cannot imagine a TJ diesel. I love the idea!
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Old 08-19-2013, 09:37 PM   #9
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So now I have to button up the wiring. Decide where to put my starter switch, oil filter, and where to splice in my coil trigger.

Then it is road testing and registration.
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Old 08-19-2013, 09:41 PM   #10
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If I had to do it over, I would have used the om617 and the kit from the mercedes 4x4 guy. I also like the diesel in the 05 liberty, but they are pricey. I sold the MB trans and various parts that paid for the car. So I got this engine free. If you don't count the labor.
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Old 08-30-2013, 11:11 AM   #11
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Had to break down and order a replacement trans since I forgot to have a trans expert bench check the old one.

Working on guages and tach. I used the TJ's 2.5L flywheel and have it mated to an ax15. The bellhousing must be just off enough that the sending unit doesn't get a good read. When I pull the trans, I will have to eyeball this better.

I wonder if anyone has just jumped the PCM and went straight to the guages? I know the dash unit is electric, but I am not certain if each guage still reads it's on signal after passing through?

I have starter wired to button and shutoff vacuum works great.

I need to wire the relay from the thermostat sending unit to the aux. fans and then battery.

Always something.

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