Mercedes turbo diesel swap - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > YJ Jeep Wrangler Forum > YJ Build Forum

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 02-02-2014, 11:48 PM   #1
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Talking Mercedes turbo diesel swap

Hey, new to the forum from VA and have been a very happy 89 yj 4.2 5 speed owner for a few years now. However the lack of reliability that the BA-10/5 is know for and the fact that it chatters has kept me on the lookout for an AX15. Well a few weeks ago my brother found me one, as well as two Mercedes OM617 5 cylinder diesels with all the adapters and mounts ( even a full exhaust that goes on the factory mounts) to put it in my YJ. Well over this weekend we were able to pull the 4.2 and trans and get the diesel and AX15 mounted up. Sorry no pics of the engine mounted yet, hopefully tomorrow.




__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 02-03-2014, 07:58 PM   #2
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
A few more pics, working on removing all unneeded wiring now. Also removing the tank to drain the gas.


__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 02-06-2014, 10:46 AM   #3
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Made some more progress, got the whole driveline hooked up, wiring is getting closer. Fuel tank is drained waiting on filler hoses. I also enlarged the filler by removing the flapper in case I have to use a large nozzle at the pump, but I'll have to go slow with it.



Also the dash, notice something? Yup, I added a glow plug symbol and covered the shift and emissions so it won't show up. My intent with this project is to make it look as stock as possible.

__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 02-06-2014, 12:19 PM   #4
Jeeper
 
TJK8's Avatar
 
Join Date: Nov 2013
Location: North Georgia
Posts: 257
Looks great...thats a ridiculously clean OM617.
__________________
TJ diesel truck build in progress. Check out my build thread...

http://www.wranglerforum.com/f118/tj...ld-383474.html
TJK8 is offline   Quote Quick Reply
Old 02-06-2014, 09:10 PM   #5
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Thanks TJK8, I spent a little time cleaning it up, checked the valves Etc. I was also happy to get one of the few years that had the turbo and no EGR. By the way, I read your whole thread, awesome build!

Got a few more goods today, I got a power steering hose from NAPA and had a new end put on so I can use the pump on the Mercedes, perfect fit.
__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 02-25-2014, 05:26 PM   #6
Livin la vida loca

WF Supporting Member
 
Join Date: Jan 2014
Location: Dallas Ore.
Posts: 169
any more progress , how heavy is the OM617
Richard_95YJ is offline   Quote Quick Reply
Old 03-06-2014, 08:02 AM   #7
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Richard_95YJ: The OM617 is about 550 lbs, or around 50 lbs heavier than a 4.2.
Sorry for slacking on an update!:cheers2: Here's some more pics of where I an with it now, still needs a little cleaning up in wiring (just some loom wrap, any unneeded wiring is already gone) and the heater hoses. Also the air cleaner and unsightly PCV hose with the plastic 90* will be going in favor of a Donaldson air cleaner and a moulded 90* hose.


Optima 800 CCA red top to light the glow plugs and spin it over in the cold. by removing the bolt on base battery holder on the passenger side the bigger battery clamps in perfect.

Here's the radiator fan, couldn't stand the idea of using the fan manufactures zip ties to mount it against the fins, so I made some brackets for it.

The YJ likes the snow I gave the chrome grille the boot and repainted the grille and did the headlight bezels in a tan, think it looks good.

Here's a quick video in the yard, 18" of snow, got warm today and it was getting really heavy, hope it works, if not let me know and I'll try and get the vid working tomorrow.


Got the gauges worked out, the oil and temp are now mechanical, so no worries there anymore.

__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 03-06-2014, 08:20 AM   #8
Jeeper
 
TJK8's Avatar
 
Join Date: Nov 2013
Location: North Georgia
Posts: 257
Nice…it sounds awesome…what exhaust are you running?

Did you relocate the factory oil filter housing?

Do you have part numbers for the NAPA hose and end you used for the power steering pressure hose?
__________________
TJ diesel truck build in progress. Check out my build thread...

http://www.wranglerforum.com/f118/tj...ld-383474.html
TJK8 is offline   Quote Quick Reply
Old 03-06-2014, 11:23 AM   #9
Grumpy Old Fart

WF Supporting Member
 
curtisreinke's Avatar
 
Join Date: Dec 2013
Location: Dahlonega, GA
Posts: 59
When you get a few minutes could you post a few details about how you mounted the gauges? I was planning to fabricate one out of aluminum that would take the place of the plastic assy behind the factory bezel. If they will mount in place of the originals I may just do that.

I want real gauges and the oil pressure will be mechanical. I have to constantly tap on the temp and volt gauge to get them to stop jumping around. That clock has to go too, the hands are so short that they hide behind the knob.
curtisreinke is offline   Quote Quick Reply
Old 03-06-2014, 01:15 PM   #10
Jeeper
 
Join Date: Jan 2013
Location: Adair Co. KY
Posts: 428
Nice looking build, I really like the idea of using the Mercedes diesel better than using a 4bt.

Quote:
Originally Posted by curtisreinke View Post
When you get a few minutes could you post a few details about how you mounted the gauges? I was planning to fabricate one out of aluminum that would take the place of the plastic assy behind the factory bezel. If they will mount in place of the originals I may just do that.
Here is an option for anyone wanting to replace gauges with aftermarket ones, its what I plan on using. Gauge Works 15218 - Gauge Works Center Gauge Pod for 87-95 Jeep® Wrangler YJ - Quadratec
__________________
My 305 swap http://www.wranglerforum.com/f8/89-y...ad-256560.html
Debating a Chevy v8 swap? read this thread
http://www.wranglerforum.com/f330/ch...l#post10826122
kywaterman is offline   Quote Quick Reply
Old 03-06-2014, 01:29 PM   #11
Jeeper
 
TSRESHA's Avatar
 
Join Date: Sep 2013
Posts: 99
Images: 2
nice, but I hate to even ask, costs?
__________________
*||||* Keep Calm & Jeep On
TSRESHA is offline   Quote Quick Reply
Old 03-06-2014, 06:28 PM   #12
Jeeper
 
Hutchings's Avatar
 
Join Date: Dec 2012
Posts: 38
I have the exact same gauge pod - 1 center and 2 for above the steering column (it doesn't come with the little center piece above the column) - that the previous owner had, but I'm not a big fan of it. (I'm looking more towards a CJ dash.) Since I don't need em, I'll sell them for a decent price. Just PM me.
Hutchings is offline   Quote Quick Reply
Old 03-06-2014, 07:53 PM   #13
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Quote:
Originally Posted by TJK8 View Post
Nice…it sounds awesome…what exhaust are you running?

Did you relocate the factory oil filter housing?

Do you have part numbers for the NAPA hose and end you used for the power steering pressure hose?
Thanks! It's just a straight pipe with a small glass pack, it sounds about right! The YJ firewall didn't require me to relocate, unfortunately from what I've researched your TJ firewall sticks out more, relocation kit are made by mercedesdiesel4x4.com . I just ordered a stock steering hose and took it to a good hydraulic shop with the Mercedes hose and he matched a end and replaced the pump side to fit the Mercedes pump, sorry I didn't save any numbers
Quote:
Originally Posted by curtisreinke View Post
When you get a few minutes could you post a few details about how you mounted the gauges? I was planning to fabricate one out of aluminum that would take the place of the plastic assy behind the factory bezel. If they will mount in place of the originals I may just do that.

I want real gauges and the oil pressure will be mechanical. I have to constantly tap on the temp and volt gauge to get them to stop jumping around. That clock has to go too, the hands are so short that they hide behind the knob.
The gauges weren't bad, remove the gauges you want to replace, take the mechanical gauge and drill the holes the housing to bolt it in, I removed to bezel and lens from the gauge too. Then its a matter of tracing and hard wiring the electric gauges you want to keep, as well as the lights. I saved the clock( I kinda like my clock, lol) fuel gauge ( I had a hard time finding a replacement for this, thus why I didn't go with the gauge cluster that kywaterman mentioned) and the amp gauge.

Quote:
Originally Posted by kywaterman View Post
Nice looking build, I really like the idea of using the Mercedes diesel better than using a 4bt.



Here is an option for anyone wanting to replace gauges with aftermarket ones, its what I plan on using. Gauge Works 15218 - Gauge Works Center Gauge Pod for 87-95 Jeep® Wrangler YJ - Quadratec
thanks!


A little update, I picked up this today, a Ramsey 8000, $150
__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 03-06-2014, 09:09 PM   #14
Jeeper
 
TJK8's Avatar
 
Join Date: Nov 2013
Location: North Georgia
Posts: 257
Quote:
Originally Posted by diesel89yj View Post
Thanks! It's just a straight pipe with a small glass pack, it sounds about right! The YJ firewall didn't require me to relocate, unfortunately from what I've researched your TJ firewall sticks out more, relocation kit are made by mercedesdiesel4x4.com . I just ordered a stock steering hose and took it to a good hydraulic shop with the Mercedes hose and he matched a end and replaced the pump side to fit the Mercedes pump, sorry I didn't save any numbers
Thanks…thats my plan as well on the hoses.

What is your gear ratio and tire size? How do you feel about the power/driveability as compared to a stock 4cyl and 6cyl wrangler?
__________________
TJ diesel truck build in progress. Check out my build thread...

http://www.wranglerforum.com/f118/tj...ld-383474.html
TJK8 is offline   Quote Quick Reply
Old 03-06-2014, 10:10 PM   #15
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Quote:
Originally Posted by TJK8 View Post
Thanks…thats my plan as well on the hoses.

What is your gear ratio and tire size? How do you feel about the power/driveability as compared to a stock 4cyl and 6cyl wrangler?
I'm running 31s with 3.07 gears, and it's geared way to high (the max torque of the Mercedes, surprisingly is 400 RPM more than the 4.2), I can run 60 in 3rd pretty easy. I need 3.73 or 4.10 as taking off uphill it takes forever to get it to spool the turbo. Power /drivability is somewhat less than the 4.2, unfortunately I've never driven a 4cyl so I can't really say. Overall I'm really happy with it, and I'm sure regearing will do wonders.
__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 03-07-2014, 07:11 AM   #16
Jeeper
 
TJK8's Avatar
 
Join Date: Nov 2013
Location: North Georgia
Posts: 257
Nice…no one ever posts about drivability. I'm planning on running 35" tires on 5.13 gears with an AX-15. If you run final drive calculations on that combo and a stock Mercedes with the 3 speed auto and 27" factory tire its within about 8% of factory so I should be right in the power band.
__________________
TJ diesel truck build in progress. Check out my build thread...

http://www.wranglerforum.com/f118/tj...ld-383474.html
TJK8 is offline   Quote Quick Reply
Old 03-07-2014, 07:24 AM   #17
Jeeper
 
Beer Belly's Avatar
 
Join Date: Jan 2014
Location: over here, not over there.
Posts: 266
Very nice. I used to work on those old M/B diesels. Great engines. The 5 cylinder single cam turbo would go 350,000 miles easy, and never had any problems. The 4 cylinder non turbo from the 240d's are great engines also and have the same reliability, but with an automatic they make the jeep 2.5l seem like a V8! Make sure you keep the valves adjusted (do it with the engine HOT), and put in a block heater. They are an absolute bear to start in the cold. The fuel return lines that go between the injectors go bad often. easy fix. The vacuum shut-off was a pain with the benz's because the door locks were vacuum actuated also, and when one hose would leak, you lost vacuum to the igt. switch. That is why there is the big red "STOP" lever on the throttle linkage. Anyway. Nice job…enjoy it.
__________________
'89 Yes it's a Junker, 2.5l, 5 speed. No A/C, no air bags, no coil springs, no radio, no GPS, No electric windows, no power seats, no carpet, no bluetooth, no back doors, no check engine light, no tpms, no automatic sway bar disconnect.
Beer Belly is offline   Quote Quick Reply
Old 03-07-2014, 07:27 AM   #18
Jeeper
 
Beer Belly's Avatar
 
Join Date: Jan 2014
Location: over here, not over there.
Posts: 266
Oh yeah….nice Cub Cadet! 128?
__________________
'89 Yes it's a Junker, 2.5l, 5 speed. No A/C, no air bags, no coil springs, no radio, no GPS, No electric windows, no power seats, no carpet, no bluetooth, no back doors, no check engine light, no tpms, no automatic sway bar disconnect.
Beer Belly is offline   Quote Quick Reply
Old 03-07-2014, 07:34 AM   #19
Jeeper
 
TJK8's Avatar
 
Join Date: Nov 2013
Location: North Georgia
Posts: 257
Quote:
Originally Posted by Beer Belly View Post
The vacuum shut-off was a pain with the benz's because the door locks were vacuum actuated also, and when one hose would leak, you lost vacuum to the igt. switch. That is why there is the big red "STOP" lever on the throttle linkage. Anyway. Nice job…enjoy it.
Speaking of this…how did you wire up your shut off for the engine? Using the factory vacuum shutoff?

Thanks for all the replies…can't wait to get mine installed!
__________________
TJ diesel truck build in progress. Check out my build thread...

http://www.wranglerforum.com/f118/tj...ld-383474.html
TJK8 is offline   Quote Quick Reply
Old 03-07-2014, 08:53 AM   #20
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Quote:
Originally Posted by Beer Belly View Post
Very nice. I used to work on those old M/B diesels. Great engines. The 5 cylinder single cam turbo would go 350,000 miles easy, and never had any problems. The 4 cylinder non turbo from the 240d's are great engines also and have the same reliability, but with an automatic they make the jeep 2.5l seem like a V8! Make sure you keep the valves adjusted (do it with the engine HOT), and put in a block heater. They are an absolute bear to start in the cold. The fuel return lines that go between the injectors go bad often. easy fix. The vacuum shut-off was a pain with the benz's because the door locks were vacuum actuated also, and when one hose would leak, you lost vacuum to the igt. switch. That is why there is the big red "STOP" lever on the throttle linkage. Anyway. Nice job…enjoy it.
Thanks for the info, I checked all the valves when I got it, only one out of adjustment. I've been pretty happy with how it starts cold amazingly, of course the new starter and optima red top helped a lot. Yeah the vacuum shutoff is a pain sometimes, I think the pump needs a rebuild because the brakes are a little weak and I have to rev it a little sometimes to get it to shut off.
Quote:
Originally Posted by Beer Belly View Post
Oh yeah….nice Cub Cadet! 128?
Actually a 1811, I'm a pretty serious cub collector, I even have two diesel 1782s. I seem to have the diesel bug
Quote:
Originally Posted by TJK8 View Post
Speaking of this…how did you wire up your shut off for the engine? Using the factory vacuum shutoff?

Thanks for all the replies…can't wait to get mine installed!
Yup, it has the vacuum shutoff, my brother actually did most of the wiring as he's much better at it than me, so I'm not sure exactly how it's wired, but it's pretty simple.
Oh, by the way, I can't wait to see yours finished, it's an awesome looking build
__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 04-20-2014, 08:30 PM   #21
Newb
 
Join Date: Apr 2014
Location: Indiana
Posts: 5
What radiator did you use and how did you mount your oil cooler?

I have my Jeep stripped out ready for the new transplant, Just picked up my 1980 300SD yesterday.
__________________
1992 YJ Om 617 conversion
1992 Dodge Ram D250 Diesel
1997 Dodge Ram 2500 4x4 Diesel
9297oldram is offline   Quote Quick Reply
Old 04-20-2014, 08:39 PM   #22
Newb
 
Join Date: Apr 2014
Location: Indiana
Posts: 5
Quote:
Originally Posted by diesel89yj View Post
Made some more progress, got the whole driveline hooked up, wiring is getting closer. Fuel tank is drained waiting on filler hoses. I also enlarged the filler by removing the flapper in case I have to use a large nozzle at the pump, but I'll have to go slow with it.



Also the dash, notice something? Yup, I added a glow plug symbol and covered the shift and emissions so it won't show up. My intent with this project is to make it look as stock as possible.


Are you using the stock Mercedes glow plug controller? If so how did you hook it up?
__________________
1992 YJ Om 617 conversion
1992 Dodge Ram D250 Diesel
1997 Dodge Ram 2500 4x4 Diesel
9297oldram is offline   Quote Quick Reply
Old 04-21-2014, 10:03 PM   #23
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Quote:
Originally Posted by 9297oldram View Post
What radiator did you use and how did you mount your oil cooler?

I have my Jeep stripped out ready for the new transplant, Just picked up my 1980 300SD yesterday.
Using a stock radiator with the cooler mounted in front of it, the previous owner rad/ oil cooler when I bought the engines.
Quote:
Originally Posted by 9297oldram View Post
Are you using the stock Mercedes glow plug controller? If so how did you hook it up?
Yup, only need to hook up three wires, one to the battery, one hooked into the on position, and one for the bulb.

Well, I've made a lot of progress, did the SYE, 8.8, driveshaft, front axle( with powertrax no slip) smittybuilt bumper/ tire carrier ( made better than I expected) removed the trans drop, all new brakes in the rear, boomerang shackles, and finished the windshield / dash. Just need shocks ( the ones the PO had on it were FULLY extended with it sitting on the ground) Here's a few pics, don't worry, I'm not done yet




__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 05-15-2014, 08:48 PM   #24
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Well the stock 4.2 radiator isn't quite enough, so I bit the bullet and got a griffin two core and a ford taurus fan for it, should be keeping cool now Hope to install it and the Donaldson air cleaner tomorrow. Finished painting it and tested the locker out a little




__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Old 05-18-2014, 07:22 PM   #25
Newb
 
Join Date: Apr 2014
Location: Indiana
Posts: 5
Do you remember the P/N for the radiator in case anyone might need to get one also?
__________________
1992 YJ Om 617 conversion
1992 Dodge Ram D250 Diesel
1997 Dodge Ram 2500 4x4 Diesel
9297oldram is offline   Quote Quick Reply
Old 06-15-2014, 03:55 PM   #26
Jeeper
 
diesel89yj's Avatar
 
Join Date: Jan 2014
Posts: 16
Yeah I have it written down, I'll post it when I get a chance. Here's everything installed.

__________________
89 YJ mercedes turbo diesel/AX15 swap in progress....
, _____
/l ,[___],
l--L --[]lllll[]-
()_) ()_)-o-)_)
14 Ram 2500 4x4 cummins 6 speed manual
diesel89yj is offline   Quote Quick Reply
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off




» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 04:17 AM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC