Sokoji's Mercedes turbo diesel swap/DD build up thing

[sokoji]

So I have been working on this for a bit. At the moment I'm swapping a OM617 into the pickup, nothing fantastic, doing it on a shoe-string budget.

Day I had it delivered.


Did the head gasket on the 22r

Put in some Hyundai Accent seats

Rolled on some Rustoleum

Made up some door cards


Got tired of the 22r being a slug so I drove this home for $400




Picked up a G54 which I thought was a W56

Stripped unessential crap off the engine

First test fit, its pretty tight in there


Had the Mercedes bolt pattern drilled in the flywheel and a pilot bearing bushing made

Started the adapter plate



Second fitting with trans bolted up

I might need to trim the hood some

My sweet plate to hold the transmission till I learn how to weld better 

My poor springs not liking the new diesel weight

Didn't think the radiator would fit in the front so I wasted my time running lines to the bed and mounting up the radiator in the bed

The engine is mounted a bit high and I'm not about to add more weight up high by adding a body lift so the hood got chopped

Thought it was about time to add these

So I never liked the idea of the radiator in the bed so I remeasured and it looks like with the mechanical fan and the radiator in the front I'll have about one inch between the fan and the radiator. Hopefully that will be enough. But it will involve pretty heavy trimming of the grill and again of the hood. Trying to use as much Mercedes stuff as possible off of the car.
Here is a pic of the radiator all mounted up.

[kipamore]

Dude! I'm doing a same, but even weirder swap myself. 1990 Toyota uhaul 1 ton with a slant six. We're done a lot of the exact same things. Check out my buildup over here:
http://slantsix.org/forum/viewtopic.php?t=39441&postdays=0&postorder=asc&start=45

I have a SLEW of tips for you, including quite a few tips on the OM617 which I have also owned in the past.

[sokoji]

Yeah any tips would be appreciated especially since this is the first diesel I have had. Looked over your build, I'm surprised you got a straight six to fit specially since I'm having so much trouble with a 5.

[79coyotefrg]

a 2 inch body lift would help you a LOT

[sokoji]

Yeah it would, doubt even a two inch would allow me to clear the radiator now. I keep going back and forth on the body lift. Right now I'm thinking a really big hood scoop/ power bulge.

[emsvitil]

What are the TQ and HP ratings of the 5-banger?

[emsvitil]

You could have a raised center grill (ram truckish) to clear the radiator, then carry that back to cover the holes in the hood.

[sokoji]

What are the TQ and HP ratings of the 5-banger?

I have been told I should expect 125hp and 170-180 torque stock. As with most diesels there are some easy ways to increase the power but this engine isn't going to be a huge power house and wouldn't expect much from an engine I picked up for $200 after selling the car parts. Also it revs up to 5k, and when I have driven it around the block, it drives just like a gasoline engine.

You could have a raised center grill (ram truckish) to clear the radiator, then carry that back to cover the holes in the hood.

Good Idea I was thinking along those lines, could also use the extra space to mount my Mercedes emblem too. I even picked up another good condition hood to skin.

[twistedtoy92]

damn very unique!!!!! Im watchin this one!!! arent parts expensive for these??

[NorCalToy]

Thats an awesome swap. I would defintely be interested to find out how much money and tim eyou have into when its all said and done. Keep up the good work on it. Cant wait to see the finished product

[hilux-1983]

Hmmm.....

[locked 4x4]

this thing is to cool.  caint wait to see it done

[sokoji]

damn very unique!!!!! Im watchin this one!!! arent parts expensive for these??

Yes the parts are expensive compared to the 22r if your buying them new. But I never intend to rebuild this engine, simply pull it out and put a better used one in. Especially since the bodies of the Mercedes usually fall appart/rust out around these engines and then they can be had for cheap. Also the junkyards I frequent don't charge based on the brand of part at all just by the type  8)

Thats an awesome swap. I would defintely be interested to find out how much money and tim eyou have into when its all said and done. Keep up the good work on it. Cant wait to see the finished product

Thanks for the kind words. Yeah I will post up prices when I'm done, but hopefully I am at the end of purchasing big items for this swap It has taken me about about two months by myself to get it to the point it is now. This also is the first time I have ever done a swap this in depth before so a lot of that time was spent learning how to make stuff and thing of how to make it all fit. Hopefully it will be semi drivable after I work on it today. 

[46&2]

Very cool swap. I would love to do this some day as I see Mercs with the OM617 for practically nothing around my parts. My friend Luke at 4x4 Labs created OM617 Merc to Chevy adapters for GM bellhousing and crank bolt pattern. You seem to have it all under control but I thought I'd pass you the link just in case. He has been running the OM617 in his FJ 40 for over a year now and loves it.

http://www.4x4labs.com/products/diesel-conversions/

Anyway I always thought this would be a cool swap to do so I will be watching this one. Nice work so far! 

[sokoji]

Yeah I saw 4X4 Labs kit, I considered it as a backup plan if I couldn't figure out how to make the plates myself, also they don't have one for Toyota transmissions yet.

So I think I might have found a grill to cover the radiator, I might just try grafting the Mercedes hood onto the Toyota.

[greeny]

nice

[sokoji]

Okay here is a video of it running.http://www.youtube.com/watch?v=s_uMDVmb0Uo Haven't figured out how to do the embedded yet.

[emsvitil]

Okay here is a video of it running.http://www.youtube.com/watch?v=NNa0E7I0RtU Haven't figured out how to do the embedded yet.

Get following error message:


This video is a duplicate of a previously uploaded video.



Got another link?

[sokoji]

Yeah sorry I was having problems uploading it. This one should be good. http://www.youtube.com/watch?v=s_uMDVmb0Uo

[46&2]

Sounds good! Are you going to find a way to put that whole grill in there or cut it down?

[sokoji]

Not sure yet, I hadn't even thought of cutting the grill down though. I'll have to kick around the ideas a bit more. I did pick up a Mercedes hood that I'm going to use to mount the grill and us for the bulge.

[46&2]

Not sure yet, I hadn't even thought of cutting the grill down though. I'll have to kick around the ideas a bit more. I did pick up a Mercedes hood that I'm going to use to mount the grill and us for the bulge.

Well either way it sounds good. Look forward to seeing what you come up with.

[THK Matt]

Ill watch

[yotarunner85]

What starter did you use and how did you get it to work with that engine trans combo? Very intresting motor swap. 

[sokoji]

I'm using the stock starter, pretty much using all stock Toyota stuff from flywheel back. It works because the diesels starter was in the same place and the Toyota starter bolts to the bellhousing of the transmission.

[sokoji]

So this is what I came up for the hood. I found out during the progress that I suck at bodywork.

[82juguete]

That is hideously awesome.  Need to see it from more angles. I say if (when) you ditch the front bumper for a stronger tube one, you just turn the signal lights vertically and relocate them into the voids on either side of the grill and call it a day. Nice work on a unique machine!

[86bobbedtoy]

dove nose it.
just grill and headlight and a mean stinger.
wish I still had the motivation you do
awesome work man!

[greeny]

amazingly original

[sokoji]

That is hideously awesome.  Need to see it from more angles. I say if (when) you ditch the front bumper for a stronger tube one, you just turn the signal lights vertically and relocate them into the voids on either side of the grill and call it a day. Nice work on a unique machine!

Here are some more angles, I left alot of room between the radiator and the grill so I would have the room to mount up an intercooler down the road. I was thinking maybe some off road lights in the voids. Definitely need a new bumper as I had to cut some of the supports to fit the radiator so now its kinda loose. Thanks for the kind comments.