OM 613 3.2 CDI swap into 80FZJ

[canman]

Interesting. I could buy an entire 80 series/LX450 for 3300€ here. I can tell you that the OM 612 (270 CDI), in the Canadian Army G Wagons was adequate at 156 Hp. Even at a GVW of 4800 kg it could move it, albeit slowly, but at the same time, overall fuel economy during testing at GVW was a very respectable 14L/100km, but it did have the 5sp auto trans. I recall we were in discussions at the time with a company in the UK to have the ECU remapped to give an additional 30Hp, but the project fell through.

 

[Tugarin]

Re-mapping using British company? It can be done pretty much by any tuning company who deals with Mercedes CDI engines.

I watch the Patrol with 3.2 CDI (same as the one going into my TLC) I have not seen the mapping. Shop guys claim they re-mapped it to 580 NMs with no issue. As soon as catch that guy I will take plenty of pictures of Patrol swap. It feels like it has way more power than turbocharged TD-42 4.2 liter Nissan stock engine.

 

[Dragos80]

There is a Polish company doing BMW diesel swaps into Patrols. They're on Facebook and have a few videos on youtube.
I guess anything can be done, for a price of course.
I think it would be easier to have en engine from a manual car due to complexity of tricking the ECU on an automatic car.

 

[Tugarin]

I have thought out my way, got things going and I will stick to it. The problem 3.2 CDI never mated with manual.

 

[Tugarin]

OK last week I had a call from these guys to witness the engine running off the pallet.

I did'not have a camera with me so I did not took the video. Engine runs well off the battery and bottle of diesel fuel . Sounds awesome and has a 1.2 bar oil pressure idling hot. Guy did a good job cutting most of the crap related to the trans and environment (EGR) Since the EGR is removed I suggested to modify the intake manifold to make it smaller and more normal shape plus we want to remove all the flaps inside of it.

Another question rose - can you guys show off your examples of intercooler location on ARB front with the winch, where did you located it? Merc's stock IC is long and straight. It will not fit the TLC without modification. We do not want any under hood location. Friend of mine had Mitsubishi Pajero with under hood IC, I think it is a joke, with no effect at all.

Right now I have new clutch set and flywheel, now sourcing out a used H151F, so guys could work on adapter pieces it without downing my TLC.

The main thing we found out that we do not need to cut the engine frame mounts - we can fit it on it's own liquid filled mounts on original TLC frame mounts with transition pieces.

So second step is complete, Mercedes CRD engine CAN and WILL run without it's body. I feel like we managed to do a surgery on someone's head and brought it to life without a body.

 

[bloc]

The main thing we found out that we do not need to cut the engine frame mounts - we can fit it on it's own liquid filled mounts on original TLC frame mounts with transition pieces.

So second step is complete, Mercedes CRD engine CAN and WILL run without it's body. I feel like we managed to do a surgery on someone's head and brought it to life without a body.

The brain surgery analogy is appropriate..

And crazy that all you need is adapter plates for the motor mounts..

 

[DHwreckage]

an air to water is probably going to be the easiest to fit, other wise you'll have to do some cutting to get the A/A intercooler piping up front

 

[alia176]

This is good info for others who maybe doing a similar swap. Would the OP mind filling out the location area on the left side of the screen? This will keep things in perspective when it comes to ordering parts, labor costs, pics, etc.

 

[Tugarin]

And crazy that all you need is adapter plates for the motor mounts..

I am trying to keep everything reversible, just in case. Plus, in another 5 years and I might want to go with OM 642 motor.

This is good info for others who maybe doing a similar swap. Would the OP mind filling out the location area on the left side of the screen? This will keep things in perspective when it comes to ordering parts, labor costs, pics, etc.

By the time of rgw swap accomplished, I will make full write up with pictures, videos, drawings for adapters, wiring and etc - I am not the one who keeps everything by his chest. Will put out the pricing, PNs and etc. And this is happening in Kazakhstan.

 

[rose351]

I am trying to keep everything reversible, just in case. Plus, in another 5 years and I might want to go with OM 642 motor.


By the time of rgw swap accomplished, I will make full write up with pictures, videos, drawings for adapters, wiring and etc - I am not the one who keeps everything by his chest. Will put out the pricing, PNs and etc. And this is happening in Kazakhstan.

Holy cow, Tugarin, this is AWESOME. I have been trying to figure out how to swap a Mercedes OM 642 motor or a VW 3.0 TDI for about a year now, and I've been studying how the maps are programmed and trying to figure out a way to get rid of some of the body control module (BCM) and transmission control module (TCM) crap that I wouldn't need. I've found a few folks that might be able to help with the CAN Bus issues as well, but it is still going to be a TON of trial and error and frustration and long nights.

The fact that you've been able to get the motor running out of the car is quite a feat! I would love to have some more information and pictures of the ECU and the process that was used to remove the 'pieces' that weren't needed. How were they able to discover which parts and pieces to remove from the ECU without destroying it? I'd like to keep the emissions in my case, but besides that it would be a standalone operation. I'm looking forward to this project with great anticipation! Congratulations on the work done so far!

-Ryan

 

[Tugarin]

I have been trying to figure out how to swap a Mercedes OM 642 motor or a VW 3.0 TDI for about a year now, and I've been studying how the maps are programmed and trying to figure out a way to get rid of some of the body control module (BCM) and transmission control module (TCM) crap that I wouldn't need. I've found a few folks that might be able to help with the CAN Bus issues as well, but it is still going to be a TON of trial and error and frustration and long nights.

Hi Ryan, in the shop there is the guy who used to work for the MiGs (jet fighter) electronic systems plant, old guy. He explained me the principal of operating of these ECMs and how he managed to strip these down. In general, without going into details there is only one unit responsible for controlling injectors which receives information from different units. There are vital information as air, fuel, RPMs, temperature, TPS and that is all needed to run CRD. Secondary units are responsible for safety/trans/environment systems which can be physically eliminated by soldering gun and wire cutter. I understand it is more than what he is saying, but at the end what they showed me was Merc's ECM with all open guts directly connected to the battery enabling the engine to run on the pallet.

Regarding the OM 642 he said it will take a year or so to figure out how the ECM runs to make it standalone unit. The shop guys opinion is that 613 and 648 are last good Mercedes engines with cast iron blocks with famous reliability. 642 has a lot of complaints and issues.

I asked shop guys on willing to go international selling the standalone Merc's ECM units for 613 and 648. They supposed to give me a answer this or next week.

I'd like to keep the emissions in my case, but besides that it would be a standalone operation. I'm looking forward to this project with great anticipation! Congratulations on the work done so far!

Why you would want to keep EGR and particulate filter? It's a motor killer. Plus then you need to keep ECM component responsible for ERG and particulate filter burner.

 

[rose351]

Hi Ryan, in the shop there is the guy who used to work for the MiGs (jet fighter) electronic systems plant, old guy. He explained me the principal of operating of these ECMs and how he managed to strip these down. In general, without going into details there is only one unit responsible for controlling injectors which receives information from different units. There are vital information as air, fuel, RPMs, temperature, TPS and that is all needed to run CRD. Secondary units are responsible for safety/trans/environment systems which can be physically eliminated by soldering gun and wire cutter. I understand it is more than what he is saying, but at the end what they showed me was Merc's ECM with all open guts directly connected to the battery enabling the engine to run on the pallet.

Regarding the OM 642 he said it will take a year or so to figure out how the ECM runs to make it standalone unit. The shop guys opinion is that 613 and 648 are last good Mercedes engines with cast iron blocks with famous reliability. 642 has a lot of complaints and issues.

I asked shop guys on willing to go international selling the standalone Merc's ECM units for 613 and 648. They supposed to give me a answer this or next week.

Unfortunately because of the year of my swap I'll have to use a 2009 or newer motor if I ever hope to get it registered in the USA. I like the idea of using one of the older inline 6 motors, but again because of the year of my donor truck it would have to be 2009 or newer which means CANBus, dpf, adblue, etc. I wonder how he figured out what he could remove and what needed to stay? Man I would kill for some garage time with this guy, I bet he could teach us so much.

Why you would want to keep EGR and particulate filter? It's a motor killer. Plus then you need to keep ECM component responsible for ERG and particulate filter burner.

I would love to go without them, but because of our ridiculous emissions regulations and the EPA here in the states, if I were to do this swap I'd have to keep all the emissions equipment in place and functional. I know they choke the hell out of the motors... I was getting 47-52mpg regularly in my 1999 a4 VW Jetta, I'm getting 40-44 in my 2011 golf. But, I'm also ok with trying to help protect the environment. I'd love to use one of the VW tdis as I have so much more experience and comfort with them, but after the recent VW scandal I think this would be too much of a hassle to deal with. That's why I'm looking more at the OM642. I've got some friends that have these in their GLKs that absolutely love them.

 

[Tugarin]

I wonder how he figured out what he could remove and what needed to stay? Man I would kill for some garage time with this guy, I bet he could teach us so much.

I think what they did is they took Merc's ECM to the MiGs plant and did full reverse engineering using modern Russian weaponry technology, as I understood they have managed to read the programming codes of Bosh and opened it. Also they have managed to do the component break down.

 

[Tugarin]

Ryan, had long Friday conversation with this guy with beer and and vodka

Keeping the environmental components will lead to keeping the LCD screen from Merc and CANbus for Urethane control, particulate filter and etc. Programming should be changed. They do cut out from normal cars the environmental systems. In general they did not like the idea.

Regarding stand alone unit for 613 will be around of $800 to 1200 depending on components required to keep and mods to connect to implanted body. These are AC control modules, winter package, speedo, tacho and etc.

The 648 standalone unit will be starting from $1000.

I am not the dealer or selling person. when mine will get finished I will place here his contacts for direct communication.

 

[Tugarin]

Finally we sorted out all the wiring, the ECU will have only ability to be read via OBD to diagnose and test. No LCD coming out to the dash. Will have only check engine light.

Immobilizer - decided to have it, there is issue with eliminating immobilizer.

Engine tested in all modes, runs fine no issues.

Now mechanical part is coming, it is going to be a PITA. Looking into possibility of custom flywheel with bolt pattern of OM 613

 

[elliofur]

Great thread! Any updates? My E320 cdi is getting very rusty and my patrol y61 has no power

 

[speyrod]

Any updates? Also interested because I will be getting a W460 with 5:33's and that 240 just won't cut it for road trips. My 80 has only reached her 2/3rd life (250k miles), still runs like a dream.

 

[Kariba]

Any update on this, i have an om 648 cdi, i need

 

[Kariba]

I want to be able to use it on mercedes w460 300gd

 

[Tugarin]

Just short update, we did everything and hit the problem of making an adapter. The adapter piece did not worked well. So finally I found the company who can make the custom flywheel. So it will be one flywheel with boltpattern of Om613 and face plate of H151F clutch.