The Mercruiser, 87FJ60 with a OM606 (1 Viewer)

[Jacobs]

Hi everyone, I've been enjoying your forum for quite some time, I don't post often but have found great help in finding FJ40 parts on here.

My name is Jake, I've been working on Land Cruisers for about 15 years now- always have and always will enjoy them. It seems recently they are mostly what I work on.

I did this conversion for a friend/customer about 1 year ago, he is still driving/wheeling it fairly often.

Finished product: Keep in mind throughout this that the owner runs a Euopean car shop, european auto tech, and he finished up a lot of the details. I was to get it running and driving and take care of the heavy work, welding, fabricating etc. Also the truck is used for hard wheeling so I don't have many pictures of it, he didn't care so much about form but certainly did function. Sorry for some of the pics, most are taken with a phone camera.

http://i231.photobucket.com/albums/ee163/jakebeggy/mercruiser.jpg

The engine was in his daily driver, a 2002 E300D I believe. It's an OM606 with the electronic injection pump, we ditched that pump for an OM603 mechanical one. It was rear ended and totaled one day, so through an insurance buyback we now have the 606.

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1232.jpg

I'll get straight to the bad stuff. 4x4 labs made the adapter plate- the guy is clearly talented and has some great tools. He helped out at first then basically was really tough to get in touch with. It took a looong time to get the adapter plate, and spacer. His setup runs (in this order) 1: engine 2: stock flexplate 3: thick flywheel spacer 4: stock 2F flywheel all bolted together with long bolts that had to come from romania or something. It's an ok setup, and all seems well except this part:

The spacer that 4x4 labs sent is on the right, the one I paid a friend to recreat is on the left.

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1210.jpg

The 4x4 labs guys CNC'd the spacer, it's machined out of aluminum. One would think CNC is great- except with this type of part the tolerances should be less than .0005; I was told by my machinist friend. There were variations of about .002 all over the spacer, and it was a dissimilar metal (aluminum loves to expand and contract under heating cycles) in a ultra critical part. So my machinist friend made a copy of the aluminum one out of steel with .0002 tolerance. (the one on the left in the above pic) I know his shop isn't pretty but he does good work and I couldn't see any variations in thickness after mic'ing it.

http://i231.photobucket.com/albums/...iser/34f8e790-3b7b-43fd-91d9-f1aad8030936.jpg

Another major issue with the OM606 is that the sump of the oil pan ends up directly above the front axle. "Just make a new oil pan", well that was my thought at first, but Mercedes used a cast aluminum pan, and about 1/3 of the pan is the lower half of the engine mounting. Also, it has a chain driven oil pump that hangs way down into the sump. I would think with enough $ one could run a jackshaft and relocate the pump to the back of the pan, and allow for a rear sump pan. The strength and accuracy of the rear mounting setup still has me scratching my head. I notched the pan and gained some additional clearance out of it.

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1276.jpg

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1278.jpg

The engine mounts were actually fairly easy, we opted to use the liquid filled factory Merc mounts, which only had one 8mm x 1.25 bolt to mount, which should be under tension or compression but it's a far cry from the 2F 10 or 12mm bolt/stud... They haven't proven to be a problem after a year.

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1263.jpg

To make sure the oil pan wouldn't hit the axle, I used these thicker poly bump stops, it looks like it would ride terrible but actually worked out really well. He hit something really hard and blew one of these out and the pan survives:

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1358.jpg

I don't have a lot of pics of the injection pump swap, but it was fairly straight forward. The only bad thing was someone dropped the pump or shipping damage- the rack had become detached from the emitter control cylinders. I didn't find this out until I tried to start it and bleeding was impossible. All the cylinders but 1 were disconnected and fuel was shut off. Anyways, figured it out eventually.

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/001.jpg

Clearance is tight to the stock intake, the 603 has more of a log style than the 606, and the 606 pump doesn't have the ALDA on it:

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/052.jpg

Installed pump, you can also see the massive oil cooler lines (2 blue ones) that Mercedes runs, I used a radiator with a built in engine oil cooler to hook it up to. The hoses were mockup hoses and could be crimped in the future...

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/044.jpg

The turbo was fairly forgiving, except that the wastegate on it runs with vacuum instead of pressure. Mercedes runs the wastegate to vacuum and an the ecu changes vacuum to the wastegate to control boost. I had suggested changing the actuator for a boost actuated one, and informed the owner of this issue. We ran it with a boost gague and a no boost control- it seems with the smaller 603 pump max boost is not an issue. I'm not sure if he finished/changed anything with that setup.

The turbo was easily clocked or rotated.

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/049.jpg

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/062.jpg

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1380.jpg

Exhaust had to switch sides due to transfer case and driveshaft:

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1382.jpg

Finished exhaust next to modified stock one, I ran the flex coupler due to the soft Merc engine mounts. The engine does move around a lot more than a 2F engine. He's running an H55 5 speed in there and it's an 87 FJ60 so it has the late model trans mount. I must say somewhere, the 606 weighs MUCH less than the 2f, I would guess 250 lbs less, maybe more.

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/059.jpg

The stock 60 radiator was not going to work with the mechanical fan (notice lower outlet in center of fan), also the reason the radiator is mounted off to the side is because that's how Mercedes set their fan mounting. I know the pics are kind of scrambled here, sorry I pulled them off of 2 separate phones...

http://s231.photobucket.com/user/jakebeggy/media/4runner/mercruiser/IMG_1327.jpg.html

 

[Jacobs]

Sorry for the mixed up pics here, I pulled these off of 2 phones. Man I need to start using a regular camera Note the oil cooler using 1/2" hose, the Germans love big oil coolers, and always make good stuff

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/045.jpg

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/046.jpg

Somewhat of a temporary air filter, but it works for now. I know K&N's are awful in the dirt.

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/064.jpg

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/067.jpg

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/069.jpg

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/073.jpg

The factory air inlet pointed straight down, right into the mess of oil cooler and fuel hoses. I made a block off plate for that and welded this 90 on to get it up where it isn't a problem:

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1355.jpg

Throttle converted from linkage to cable:

http://s231.photobucket.com/user/jakebeggy/media/4runner/mercruiser/022.jpg.html


http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1361.jpg

I used the factory FJ60 soft mounts then made a cradle and mounted everything to that. The black one is P/S that he had installed while it had the 2F. The factory A/C condensor did fit, it has A/C now, I don't have pics though.

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1408.jpg

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1411.jpg

http://i231.photobucket.com/albums/ee163/jakebeggy/4runner/mercruiser/IMG_1412.jpg

Sorry for the picture quality, and lack of. I get a lot of questions about this setup, hopefully this answers some of them.

Fan shroud, wiring details etc were also later completed, but I don't have pictures.

 

[Jacobs]

A few other things to note, the 603 pump shuts the engine off with vacuum, with some clever use from a VSV I was able to get it to shut off using 12V.

The transmission I was able to retain the factory crossmember but had to modify it. It really was a matter of straightening out the engine so it wasn't mounted diagonally if you will.

Glow plugs have to be hooked up, I just ran them to a momentary button and a Ford starter solenoid since an ECM has controlled them since about 1970. This works fine, but they like to be run for a few seconds on and off while the engine is warming up. It rattles really loud if you don't until warmed up. Common mod on old Mercedes diesels when the ECM fails.

You have to buy the injection pump lock tool to swap the injection pump. I guess you could get by without it, but I wouldn't attempt it. I borrowed it from an employee at the owners shop. The timing is done by an AB light (search around)- but I assume I got it so close it was fine, or they re-set it.

From talking with the owner, I would expect 18-25 mpg out of a 606 with a 603 pump, depending on tire size, lift driving conditions etc, and it's not a cheap swap.

The engine sounded just perfect. Sounds like it belongs in there, it had the Merc diesel rattle quite nicely, but not obnoxious. It makes tons of power, WAY more than a healthy cammed 2F, but is a bit sluggish while the turbo spools up. The wastegate defaults to open so if you try to drive it without boost control, it's a complete dog.

I have the spacer and adapter plate in a CAD file, I paid to have it copied- I'm not going to steal 4x4 labs work, but if I can't get him to make me one in under 6 months, I have options... Now to figure out that pesky pan and do this high class style to a really clean cruiser, I think that would really be just a killer setup.

 

[vica153]

Awesome! I've collected the parts, so hopefully my FJ60 will be OM606 powered in a few months.

Does it have any lift? I was hoping my OME lift would give me enough clearance to have decent suspension travel after some pan modifications.

 

[Jacobs]

It has an OME 3" lift, but has a lot of extra weight, ARB, winch, partial exo cage, internal cage, 1/4" skids etc so it really looks to me like only 1.5" of lift. You just have to be sure to limit your uptravel so the pan won't hit

 

[snobdds]

You got some skilz...

I take it this is more of a profession and not a hobby?

Also, why the OM606 as opposed to an om602/603?

 

[Jacobs]

You got some skilz...

I take it this is more of a profession and not a hobby?

Also, why the OM606 as opposed to an om602/603?

Thank you much! It's truly a hobby that turned into a profession, it's all I've been doing for $ for about 7 years now.

The 606 the owner got from an insurance buyback from his totaled daily driver, after doing some research the 606 is very robust compared to the 603. The late model 603's are pretty good from my understanding but the 606's are TOUGH.

The guys in this video are running a stock block 606 with a modded 603 pump, there is some BS in the video but it's pretty entertaining when he gets on the ragged edge of the 606 imo:

http://www.youtube.com/watch?v=CJK3z4E6slc

 

[vica153]

The OM606 is 4 valve per cylinder and DOHC, while the OM603 is 2 valve and SOHC. The head issues of the OM603 were fixed for the OM606. The fact that you can bolt on the OM603 injection pump makes it it pretty much as good as it gets for simple, mechanical, run-on-anything, IDI diesels.

 

[Wheelingnoob]

Very nice swap! Im very impressed.

 

[ToyRoverlander]

The OM606 is an awesome engine!

A guy a know put one in an old mark1 VW Jetta. IP is from the OM603 as well, with bigger elements in it.
With the original turbo it now puts out 277bhp and 618NM on the dyno. He has got an HX35 for it that has yet have to be bolted on


Not my sort of car nor driving style but here's a video of it:
http://www.youtube.com/watch?v=7Qe5tXu0CTE

 

[vica153]

More like this:

 

[Tapage]

would love to see this OME606 working .. any vid .?

 

[BigRed40]

Very nice build! I've been eyeballing some OM motors lately. I already have a 4b though, so I will have to wait until after it goes in one of the vehicles... Sigh... Too many darn projects

 

[Dougal]

Great work. It's not often you can swap to a diesel engine and lose weight.

How long has it been running? Any unforeseen issues? What power/torque/boost do you expect to have?

 

[Jacobs]

Thanks guys,

I don't have any videos, well I have one of it starting for the first time without an intake (can't access the injection pump timing with it on) but the quality is poor. I know he sent me one wheeling it but I can't seem to find it.

He has been driving it for almost a year now, no issues and the guy is really hard on stuff. He came out to test drive it before it was really complete and was blasting down a nasty dirt road teasing redline much faster than I care to go- "Better if it breaks now than when I'm in the middle of nowhere!"

I would guess the power to be 170 hp 260 ft lbs from what I read, but honestly it feels like more. I drove it about 30 miles after it was finished and it pulls very hard, especially in 4th and 5th gear compared to a 2F. There is a lot of information one way or another, some say a turned up 603 pump with the 5.5 emitters flows more fuel than the electronic 606 pump. Adjusting the ALDA made a huge improvement in spool time but starts to blow a lot of black smoke before boost builds if you get carried away.

 

[Jacobs]

Very nice build! I've been eyeballing some OM motors lately. I already have a 4b though, so I will have to wait until after it goes in one of the vehicles... Sigh... Too many darn projects

I would be quite happy with a 4BT, I put a 6BT in my daily driver, an older F350 crew cab- I'm a big fan of the cummins. As I understand it the height is an issue as well in a landcruiser? I'd love to do a P pump 4bt in a pig with a NV4500 and a split t-case.

If you're curious about the "Forge" I took much better pictures and have a really good writeup on it here: http://www.ford-trucks.com/forums/1...93-cummins-nv4500-gear-vendors-and-np205.html

 

[warpdriv]

Very cool!! I had a 99 E300 with that engine and it was smoooooooth!!! It looks like the 603 IP cleaned up the fuel line routing. Was there any other electronics involved?

 

[orangefj45]

Very nice work! And thanks for posting up about this swap. I wouldn't mind doing a 606 with the 603 pump in a cruiser. Maybe I need to start a fire under Luke's ass to make these adapters readily available.
The steel spacer is a great idea as well.

Big props.

Georg @ Valley Hybrids

 

[Jacobs]

Very nice work! And thanks for posting up about this swap. I wouldn't mind doing a 606 with the 603 pump in a cruiser. Maybe I need to start a fire under Luke's ass to make these adapters readily available.
The steel spacer is a great idea as well.

Big props.

Georg @ Valley Hybrids

Thanks! We have got to get him to at least finish the spacer on a lathe, the mill just didn't have the required tolerance, and I think steel is much more appropriate. He is a good guy, very inventive. I also had to cut a notch in the adapter plate for the clutch slave cylinder to fit and one bolt hole was off about 40 thou. You know though, I've installed aftermarket bumpers sold by the thousands that require more modification to fit, so props to Luke!

Edit, I also added the dowel pin to the spacer to match the stock dowel pin in the flywheel. Luke machined the flywheel for the Merc bolt pattern and that turned out perfect though. I think that's a good addition, we also used the dowel pin on the Merc crank so the spacer is dowel pinned at both ends, but I think he had that already.

 

[69rambler]

Nice work on the install. Looks well thought out.

Sorry to be off topic, but what is your impression going from a stock cam to the Colt cam in your Cummins truck?