Jeep Wrangler YJ om606 swap

Naturally-aspirated

13

11-01-2018, 06:31 PM #1

I wanted to go with the om603 pump, but realized I don't want to fuck around the fuel delivery adjustment and not that controllable emissions to make it road legal.

I decided to buy the Baldurs DSL1 and sold the om603 pump on ebay to finance the DSL1 purchase.

[Image: TiBnQk9.jpg]

I have since put a lot of accessories and sandblasted everything.

I started (and almost finished) drawing my own adapter in solidworks with help of some of the members here, but given my now employed ass and lack of will to put together the assembly at least a dozen times to get everything were it needs to be I chose to go with a commercial adapter package.

I ordered the OM606 to AX15 adapter from mercedesdiesel4x4. That thing was expensive AF to get to EU, totaling about 1200EUR. There are some engineering choices I do not agree with and some parts of the workmanship leave more to be wanted for the price. The starter was not fitting well and had to be ground out. The allegedly "good to go" flywheel had to have 8grams removed to balance it. It feels like it is made out of a very soft steel and all the 8.8 hardware that's included for the flywheel given the length of the spacer+flywheel assembly seems sketchy. The weld marks on the plates seem like they have been stuck together with an empty gas tank. I got the adapter anodized to not look like a turd after one day of our salty road experience.

[Image: 3WwK6Qv.jpg]

I have put the engine together without the flywheel till I buy proper bolts for test fitment to measure the motor mount location. I decided to use the standard W210 om606 oil filled mounts.

[Image: NgFUp1r.jpg]

But first have to remove the old turd out.

[Image: Cd52pKI.jpg]

Old mounts plasma cut off:

[Image: dnS25qH.jpg]

Then a test fit of the new engine:

[Image: ZIRewIm.jpg]

Of course the oil pan hits the diff, even with my absurd amounts of lift everywhere Sad

I have since sourced the om648 oil pan, dipstick and the oil pump to remedy this.

[Image: 3oS5no0.png]

I drew up mounts for the engine and did a test fit for a different revision made out of lasercut plywood and hot glue.

[Image: LgDZxFf.jpg]

I sent the files to bet cut and am now waiting for them to be done and hope to be able to install them over the weekend.

I have to have this thing made pretty proper and have to submit drawings and calculations to the local road authority to make it street legal.

One of the om648 oil pump gears has shit in it, but whatever, if should be working longer than the engine.

[Image: Ohrve4g.jpg]

Was changing the oil pan but am missing an o ring that seals the pump to the block and will only be able to continue tomorrow.

[Image: 9veiqIa.jpg]

Whatever, got a new turbo core:

[Image: 75gJ0Wi.jpg]

I will try to keep this thread updated regularly and would appreciate any advice as I go along as the hardest work is still ahead- water, vacuum, wiring, fuel, ECU maps, etc.

This post was last modified: 02-11-2022, 12:34 PM by skrubis.