Builds Mercedes OM606 Turbodiesel into FZJ80 with stock trans

Discussion in 'Diesel Tech / 24 volts' started by anothernord, May 11, 2018.

  1. anothernord

    anothernord

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    You know what I don't like doing? Unnecessary work.


    The harness doesn't need to be completely hacked apart for this swap. The stock loom is well-protected and routed nicely along the firewall, so I decided just to cut un-needed plugs off the main harness (making sure to properly insulate, and depin and 12v lines to reduce electrical noise).

    Harness before

    Harness after (can you spot the differences?)

    My goal was to make the electronics be plug-and-play, so I sourced the OEM ECU plug for the 1FZ (I have these available for purchase if anyone wants one)

    This plug will connect to the DSL1 (engine ECU) and the Microsquirt (transmission ECU).
     
    Last edited: Oct 5, 2018
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  2. anothernord

    anothernord

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    Update, the DSL1 is fully wired in, all gauges work, and I should be able to put around the neighborhood tonight.

    The big stuff left to do is:

    install and plumb intercooler
    Fab exhaust
    Install transmission controller

    A note on the last item: automatic transmissions like the A343f still work without electronics, you can manually shift P, R, N, D, 2, and L, you just don't get overdrive. So for all you "I hate electronics and I want a manual so my auto trans wont get water in the ecu on the trail or if an alien invasion with EMP happens my manual will still get me out" guys, just remember that an 80 series auto will still get you around in fully-mechanical mode.

    Didn't have the nice camera for these shots:
     
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  3. anothernord

    anothernord

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    The exhaust is fabbed to the point where I'm comfortable driving it. Getting closer!

    I made 2 cuts in the stock downpipe, and re-welded to fit perfectly where the OEM exhaust routes. The cat is tucked neatly above the lower pinch welds and doesn't affect clearance like the original setup.


    Here's the shortened/lengthened driveshafts.

    I removed the MAF and cut the flange off to fit the 3.5" intake coupler
     
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  4. Nikkormat

    Nikkormat

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    Updates! We demand updates!

    Do you think that transmission adapter your designed would theoretically work with a manual like an R151?
     
  5. anothernord

    anothernord

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    I will post updates later today or tomorrow, have no fear!

    The adapter is only designed for the automatic transmission. Just because of the fundamental difference between clutch/flywheel and torque converter/flex plate makes them incompatible. It wouldn't be too hard to design a setup for the R151F or something though.
     
  6. anothernord

    anothernord

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    Leaks I have been fixing instead of updating this thread. Most of them are my own doing in combination with Murphy's law.

    Oil leaking from the BSPT to NPT connection where I threaded the Toyota oil pressure sender into the Mercedes oil filter housing
    Coolant from the lower radiator hose
    Diesel leaks from pretty much all the stupid plastic injection pump hoses
    Coolant from the defective and warped "genuine Mercedes OEM" fuel heater"
    Oil pouring from a cheap eBay -10 AN 90 fitting
    Power steering fluid from the steering box

    I took a break from being drenched in all types of fluids to wire in the controls suite.

    Major components include:
    Stock ECU adapter plug
    DSL1 engine controller
    Microsquirt transmission controller
    Microsquirt high side driver for the solenoids
    An Arduino uno for the interface to the OEM Park/neutral switch


    I decided I wanted to add some future I/O to the harness, so I stripped it and added in/removed all the unnecessary wires.

    Before:

    After many hours and 3 rolls of electrical tape:

    The engine bay is mostly done, including my TMOC (top mount oil cooler), which will have a hood scoop (because I'm a Subaru dudebro at heart).


    I wandered around the local NAPA until I found the perfect lower radiator hose. It fits great with a bit of trimming.

    Next up is to get the transmission controller tuned, and re-tune the DSL1 for altitude, then big tires, lift and snowbashing!
     
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  7. supracrazy

    supracrazy

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    The project looks great. How much interference did the OM606 have with the fire wall? Also what would you charge for the three adapters?
     
  8. anothernord

    anothernord

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    I'm running out of time in my current garage, so I took some time to get an OME 851/860 lift with Fox IPF 2.0 shocks installed.

    Scariest step: pressing out old radius arm bushings:

    KIMG2614.jpg
     
  9. bugsnbikes

    bugsnbikes SILVER Star

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    What happened with the lower radiator outlet and 606fan clearance? Did u shift things around to clear or use a smaller fan etc? (It appears the 80 radiator is in the stock position in those pics)
     
  10. absalom

    absalom

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    Dude, LCA bushings are TERRIFYING on these trucks!!
     
  11. anothernord

    anothernord

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    I didn't have to move the radiator or fan. The stock 606 fan clears the radiator just fine, but the 80 shroud doesn't quite fit so I'll need to fab something or just go with a couple big electric fans.
     
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