Diesel Engine Swap in an XJ?
CF Veteran
Joined: Jul 2010
Posts: 1,971
Likes: 5
From: WNY
Year: 1999
Model: Cherokee
Engine: 4.0 High Output
one of those down the street from me... there was one last year at the dealer... someone swapped a 5.9 cummins in it... made the stacks work for real... lol...
try using searchtempest.com... set it for unlimited distance or whatever... and use key words "cherokee diesel" search it every once in awhile and youll find one... last i checked there was one in OK somewhere... that how i found that one the state put a 4BT in...
try using searchtempest.com... set it for unlimited distance or whatever... and use key words "cherokee diesel" search it every once in awhile and youll find one... last i checked there was one in OK somewhere... that how i found that one the state put a 4BT in...
Newbie
Joined: Jan 2010
Posts: 4
Likes: 0
From: England, Carnforth
Year: 1997
Model: Cherokee
Engine: 2.5 Turbo Diesel Ltd
It was orginally a marine engine? Did not know that....how much do those engines usually run in a junk yard over there and do they use the same manual transmissions over there AX-5/AX-15? I almost thought of pricing one out and getting the computer for it then just swapping it in since its made to fit the XJ.
This is a link to me green laning in my diesel in the lake district cumbria on youtube.
Personally I love the diesel as it gives me best of both worlds especially with the cost of fuel in England and the fact a diesel engine is better in wet conditions and wadding in water as you have no electric problems with no spark plugs or HT leads.
CF Veteran
Joined: Jul 2010
Posts: 1,971
Likes: 5
From: WNY
Year: 1999
Model: Cherokee
Engine: 4.0 High Output
I have just had a look on the UK Ebay and they vary from £100 to £195 UK Pounds which I s probably around $200 to $300 american dollars. You could actually buy a whole Jeep cherroke XJ diesel over here for $500 to $1000 dollars as parts are ridiculously expensive, would just cost you a fortune to ship one over. I don't know what year they made the XJ until in America but it was 2001 over here. It is also the same gearbox and running gear as far as I am aware just mated to the VM Motori engine.
This is a link to me green laning in my diesel in the lake district cumbria on youtube.
http://www.youtube.com/watch?v=IW2i8iTVx0Q
Personally I love the diesel as it gives me best of both worlds especially with the cost of fuel in England and the fact a diesel engine is better in wet conditions and wadding in water as you have no electric problems with no spark plugs or HT leads.
This is a link to me green laning in my diesel in the lake district cumbria on youtube.
http://www.youtube.com/watch?v=IW2i8iTVx0Q
Personally I love the diesel as it gives me best of both worlds especially with the cost of fuel in England and the fact a diesel engine is better in wet conditions and wadding in water as you have no electric problems with no spark plugs or HT leads.
MJ>XJ
Joined: Mar 2009
Posts: 17,836
Likes: 7
From: Griffin, G.A.
Year: 1990
Model: Comanche
Engine: 4.0 I6
been through 2 of them... pretty sure if you shred money fine enough... they will run off it...
Newbie
Joined: Apr 2012
Posts: 3
Likes: 0
Model: Cherokee
I am interested in putting a Mercedes om617 into my 87 XJ which I believe has an AW4. A lot of the recommendations I have seen thus far have suggested that the 617 is best suited with an AX15 or a NV4500. My question is, is it possible to use the current transmission, or will I need to swap?
MJ>XJ
Joined: Mar 2009
Posts: 17,836
Likes: 7
From: Griffin, G.A.
Year: 1990
Model: Comanche
Engine: 4.0 I6
Wish I could help ya bud... Dont know anyone thats done it... Much less on this forum... Gonna have to find someone thats done it and probly call them asking question... Lol
CF Veteran
Joined: Jul 2010
Posts: 1,971
Likes: 5
From: WNY
Year: 1999
Model: Cherokee
Engine: 4.0 High Output
Agreed....and if all possible just swap the mercedes tranny in there but itd have to be rwd only from there on in and itd need a custom cross member...I'd shoot for the AX-15. Much better...but thats IMO
Newbie
Joined: Aug 2012
Posts: 6
Likes: 0
From: Northern WI
Year: 1998
Model: Cherokee
Engine: 4.0L
I owned an OM617 swapped XJ. It retained the AW4 with custom adapter. No it is not an easy swap. It's VERY VERY hard/expensive to do really well. By well I mean not a hack job. The motor has a front sump, not a rear like any motor made for a front motor 4x4. That as well as it being a Mercedes and EVERY PART UNDER THE SUN IS EXPENSIVE make it less than ideal and a general pita. When my XJ was VERY near completion, my head gasket went in glorious fashion during a stroll around town. I never got accurate MPG estimate as my gauges were not all working. I put maybe 100-200 miles on it after swap. I lost steam after the motor went and I sold it to a real nice guy near me. I don't know where the project is at the moment. I just didn't have the heart to basically start over again.
IMO, having owned the combo in question, the OM617 is not a great fit (physically and end result). It feels gutless out of boost, even with tinkering. Much higher gears are needed to get it to spin with gusto and then you loose the MPGs you are after. It is fun in boost though. With heavy tweaking I hear they really wake up, but I wanted it for reliability. I would not chose this motor again for a 4x4. I bet it is sweet in a smaller manual trans Merc though.
Having the goal of high MPGs and still a multipurpose 4x4 is MUCH harder than simply going for high MPGs and requires much more thought. That being said, I think most results fail to excite since they do not retain the original purpose of the XJ. It is VERY good all around SUV without being bulky and is excellent off road. A successful diesel swap needs to augment these aspects while still increasing the MPGs.
For my money, the B3.3T would work great for a stock to mild build, and a 4BT would suite well for a bigger build. There are some motors that can replace these but very very few in the US offer the useful power and general availability and ease of service as these. If I did a diesel on my current XJ (swapped my blown up diesel one for this one), it would be a 4BT. Very easy to find, and very easy to find parts. That means they will still be easy 10 years from now when I'd need to service it.
I have investigated the 6.2 as a plausible option, but the engine bay in the XJ could very likely make this hellish. From what I've seen the internet is very uninformed about this motor in general. It may be an option as SBC swaps are not exactly rare, and this is in that realm of fitment. I have heard of this combo being tried, but have never seen pictures. If anyone has any, PM me.
IMO, having owned the combo in question, the OM617 is not a great fit (physically and end result). It feels gutless out of boost, even with tinkering. Much higher gears are needed to get it to spin with gusto and then you loose the MPGs you are after. It is fun in boost though. With heavy tweaking I hear they really wake up, but I wanted it for reliability. I would not chose this motor again for a 4x4. I bet it is sweet in a smaller manual trans Merc though.
Having the goal of high MPGs and still a multipurpose 4x4 is MUCH harder than simply going for high MPGs and requires much more thought. That being said, I think most results fail to excite since they do not retain the original purpose of the XJ. It is VERY good all around SUV without being bulky and is excellent off road. A successful diesel swap needs to augment these aspects while still increasing the MPGs.
For my money, the B3.3T would work great for a stock to mild build, and a 4BT would suite well for a bigger build. There are some motors that can replace these but very very few in the US offer the useful power and general availability and ease of service as these. If I did a diesel on my current XJ (swapped my blown up diesel one for this one), it would be a 4BT. Very easy to find, and very easy to find parts. That means they will still be easy 10 years from now when I'd need to service it.
I have investigated the 6.2 as a plausible option, but the engine bay in the XJ could very likely make this hellish. From what I've seen the internet is very uninformed about this motor in general. It may be an option as SBC swaps are not exactly rare, and this is in that realm of fitment. I have heard of this combo being tried, but have never seen pictures. If anyone has any, PM me.
Last edited by jrobz23; Aug 13, 2012 at 08:50 PM.
CF Veteran
Joined: Mar 2010
Posts: 6,685
Likes: 6
From: Jacksonville, FL
Year: 92
Model: Cherokee
Engine: 4.0
Originally Posted by jrobz23
I owned an OM617 swapped XJ. It retained the AW4 with custom adapter. No it is not an easy swap. It's VERY VERY hard/expensive to do really well. By well I mean not a hack job. The motor has a front sump, not a rear like any motor made for a front motor 4x4. That as well as it being a Mercedes and EVERY PART UNDER THE SUN IS EXPENSIVE make it less than ideal and a general pita. When my XJ was VERY near completion, my head gasket went in glorious fashion during a stroll around town. I never got accurate MPG estimate as my gauges were not all working. I put maybe 100-200 miles on it after swap. I lost steam after the motor went and I sold it to a real nice guy near me. I don't know where the project is at the moment. I just didn't have the heart to basically start over again.
IMO, having owned the combo in question, the OM617 is not a great fit (physically and end result). It feels gutless out of boost, even with tinkering. Much higher gears are needed to get it to spin with gusto and then you loose the MPGs you are after. It is fun in boost though. With heavy tweaking I hear they really wake up, but I wanted it for reliability. I would not chose this motor again for a 4x4. I bet it is sweet in a smaller manual trans Merc though.
Having the goal of high MPGs and still a multipurpose 4x4 is MUCH harder than simply going for high MPGs and requires much more thought. That being said, I think most results fail to excite since they do not retain the original purpose of the XJ. It is VERY good all around SUV without being bulky and is excellent off road. A successful diesel swap needs to augment these aspects while still increasing the MPGs.
For my money, the B3.3T would work great for a stock to mild build, and a 4BT would suite well for a bigger build. There are some motors that can replace these but very very few in the US offer the useful power and general availability and ease of service as these. If I did a diesel on my current XJ (swapped my blown up diesel one for this one), it would be a 4BT. Very easy to find, and very easy to find parts. That means they will still be easy 10 years from now when I'd need to service it.
I have investigated the 6.2 as a plausible option, but the engine bay in the XJ could very likely make this hellish. From what I've seen the internet is very uninformed about this motor in general. It may be an option as SBC swaps are not exactly rare, and this is in that realm of fitment. I have heard of this combo being tried, but have never seen pictures. If anyone has any, PM me.
IMO, having owned the combo in question, the OM617 is not a great fit (physically and end result). It feels gutless out of boost, even with tinkering. Much higher gears are needed to get it to spin with gusto and then you loose the MPGs you are after. It is fun in boost though. With heavy tweaking I hear they really wake up, but I wanted it for reliability. I would not chose this motor again for a 4x4. I bet it is sweet in a smaller manual trans Merc though.
Having the goal of high MPGs and still a multipurpose 4x4 is MUCH harder than simply going for high MPGs and requires much more thought. That being said, I think most results fail to excite since they do not retain the original purpose of the XJ. It is VERY good all around SUV without being bulky and is excellent off road. A successful diesel swap needs to augment these aspects while still increasing the MPGs.
For my money, the B3.3T would work great for a stock to mild build, and a 4BT would suite well for a bigger build. There are some motors that can replace these but very very few in the US offer the useful power and general availability and ease of service as these. If I did a diesel on my current XJ (swapped my blown up diesel one for this one), it would be a 4BT. Very easy to find, and very easy to find parts. That means they will still be easy 10 years from now when I'd need to service it.
I have investigated the 6.2 as a plausible option, but the engine bay in the XJ could very likely make this hellish. From what I've seen the internet is very uninformed about this motor in general. It may be an option as SBC swaps are not exactly rare, and this is in that realm of fitment. I have heard of this combo being tried, but have never seen pictures. If anyone has any, PM me.
MJ>XJ
Joined: Mar 2009
Posts: 17,836
Likes: 7
From: Griffin, G.A.
Year: 1990
Model: Comanche
Engine: 4.0 I6
Originally Posted by jrobz23
I owned an OM617 swapped XJ. It retained the AW4 with custom adapter. No it is not an easy swap. It's VERY VERY hard/expensive to do really well. By well I mean not a hack job. The motor has a front sump, not a rear like any motor made for a front motor 4x4. That as well as it being a Mercedes and EVERY PART UNDER THE SUN IS EXPENSIVE make it less than ideal and a general pita. When my XJ was VERY near completion, my head gasket went in glorious fashion during a stroll around town. I never got accurate MPG estimate as my gauges were not all working. I put maybe 100-200 miles on it after swap. I lost steam after the motor went and I sold it to a real nice guy near me. I don't know where the project is at the moment. I just didn't have the heart to basically start over again.
IMO, having owned the combo in question, the OM617 is not a great fit (physically and end result). It feels gutless out of boost, even with tinkering. Much higher gears are needed to get it to spin with gusto and then you loose the MPGs you are after. It is fun in boost though. With heavy tweaking I hear they really wake up, but I wanted it for reliability. I would not chose this motor again for a 4x4. I bet it is sweet in a smaller manual trans Merc though.
Having the goal of high MPGs and still a multipurpose 4x4 is MUCH harder than simply going for high MPGs and requires much more thought. That being said, I think most results fail to excite since they do not retain the original purpose of the XJ. It is VERY good all around SUV without being bulky and is excellent off road. A successful diesel swap needs to augment these aspects while still increasing the MPGs.
For my money, the B3.3T would work great for a stock to mild build, and a 4BT would suite well for a bigger build. There are some motors that can replace these but very very few in the US offer the useful power and general availability and ease of service as these. If I did a diesel on my current XJ (swapped my blown up diesel one for this one), it would be a 4BT. Very easy to find, and very easy to find parts. That means they will still be easy 10 years from now when I'd need to service it.
I have investigated the 6.2 as a plausible option, but the engine bay in the XJ could very likely make this hellish. From what I've seen the internet is very uninformed about this motor in general. It may be an option as SBC swaps are not exactly rare, and this is in that realm of fitment. I have heard of this combo being tried, but have never seen pictures. If anyone has any, PM me.
IMO, having owned the combo in question, the OM617 is not a great fit (physically and end result). It feels gutless out of boost, even with tinkering. Much higher gears are needed to get it to spin with gusto and then you loose the MPGs you are after. It is fun in boost though. With heavy tweaking I hear they really wake up, but I wanted it for reliability. I would not chose this motor again for a 4x4. I bet it is sweet in a smaller manual trans Merc though.
Having the goal of high MPGs and still a multipurpose 4x4 is MUCH harder than simply going for high MPGs and requires much more thought. That being said, I think most results fail to excite since they do not retain the original purpose of the XJ. It is VERY good all around SUV without being bulky and is excellent off road. A successful diesel swap needs to augment these aspects while still increasing the MPGs.
For my money, the B3.3T would work great for a stock to mild build, and a 4BT would suite well for a bigger build. There are some motors that can replace these but very very few in the US offer the useful power and general availability and ease of service as these. If I did a diesel on my current XJ (swapped my blown up diesel one for this one), it would be a 4BT. Very easy to find, and very easy to find parts. That means they will still be easy 10 years from now when I'd need to service it.
I have investigated the 6.2 as a plausible option, but the engine bay in the XJ could very likely make this hellish. From what I've seen the internet is very uninformed about this motor in general. It may be an option as SBC swaps are not exactly rare, and this is in that realm of fitment. I have heard of this combo being tried, but have never seen pictures. If anyone has any, PM me.
Any information about the 6.2 can be found in the two diesel page books... I still wanna do this and might if i ever get money back right lol... Ill take full notes here of course... If i ever get over seas ill be doing it for sure... The 6.2 is an awesome engine... Plenty for offroad and reliability... Just not good for the drag strip...
Newbie
Joined: Aug 2012
Posts: 6
Likes: 0
From: Northern WI
Year: 1998
Model: Cherokee
Engine: 4.0L
Early Engine Bay Pic
In all honesty I don't have all that many of the engine bay..
The is version .1b of the front suspension. You'll see how the sump will wreak havoc.
Front sump = bad
In all honesty I don't have all that many of the engine bay..
The is version .1b of the front suspension. You'll see how the sump will wreak havoc.
Front sump = bad
Junior Member
Joined: Feb 2012
Posts: 90
Likes: 0
From: UK
Year: 2000
Model: Cherokee
Engine: 4.0l
Like Matt72 says, most of the XJ's over here are Diesel (2.5 VM). When they first came out here in 93 I think, they were either V6 3.7l or 4.0l. Not good in the UK as our petrol is very expensive, so is diesel but when you get twice the MPG and the possibility of making your own from waste veg oil they were much more attractive. The VM is notorious for heads blowing. Later Jeeps have the 2.7 Merc engine which is excellent in all respects.
I think nearly half the new cars sold in the UK are diesel now, but the engines are so much better than 20yrs ago. They are nearly all turbocharged and intercooled, common rail injection etc..very quiet, powerful and smooth and much nicer to drive than petrol cars.
One thing that we do with big petrol engines like in Jeeps etc, is to convert to LPG, this is half the price of diesel, but it does mean having two tanks and loads of extra crap under the bonnet.
The 4.0l lacks the low down punch of TDi's but once its moving I think it's great, just pretty bad on mpg's especially when towing!
Here is a 2.5 td that sold near me recently on ebay
http://www.ebay.co.uk/itm/1809462359...84.m1438.l2649
Ok its got issues but good for spares or fix it up. Approx $600. There are loads for under £1000.
I think nearly half the new cars sold in the UK are diesel now, but the engines are so much better than 20yrs ago. They are nearly all turbocharged and intercooled, common rail injection etc..very quiet, powerful and smooth and much nicer to drive than petrol cars.
One thing that we do with big petrol engines like in Jeeps etc, is to convert to LPG, this is half the price of diesel, but it does mean having two tanks and loads of extra crap under the bonnet.
The 4.0l lacks the low down punch of TDi's but once its moving I think it's great, just pretty bad on mpg's especially when towing!
Here is a 2.5 td that sold near me recently on ebay
http://www.ebay.co.uk/itm/1809462359...84.m1438.l2649
Ok its got issues but good for spares or fix it up. Approx $600. There are loads for under £1000.
Last edited by Fruid; Aug 14, 2012 at 10:25 AM. Reason: forgot something
Member
Joined: Jul 2013
Posts: 143
Likes: 1
From: San Diego, CA
Year: 1995
Model: Cherokee (XJ)
Engine: AMC 4.0
Bit of an old post but I was looking into an engine swap for my Cherokee down the road. I've read about people taking the diesel from either a liberty or a patriot, I can't remember which. That and I just read that Banks had a prototype or something along those lines that was a turbocharged diesel with the transmission and transfer case. I'm not sure if they were just showing it off to be offered in a car or if it could be bought separately.