Om617 diesel swap ?
Herp Derp Jerp
Joined: Nov 2011
Posts: 18,251
Likes: 17
From: Parham, ON
Year: 1999
Model: Cherokee
Engine: 4.0L OBD-II
So much misinformation in this thread...
Except for these bits:
The guys at http://www.mercedesdiesel4x4.com/ can probably help you out a fair bit, they've done a number of YJ conversions. One of them dragged out a conversion to whatever that show in PA is a couple months ago... I think XJwonders and PocketsEmpty were both there... can't remember the name lol.
Fab is going to be required for the engine mounts, and you'll have to figure out track bar clearance as the OM617 is a front-sump design. Overall it's the most practical choice for an XJ. No reinforcements required, similar power curve, similar weight. Nowhere near as in-depth as a Cummins or VW engine.
You've put an OM617 in? These are my motivators too. (Though I intend to make proper biodiesel to run everything off of)
Except for these bits:
To do the swap you can get a adapter from http://www.mercedesdiesel4x4.com/category_s/1831.htm and http://www.4btswaps.com/forum/showth...okee-Questions
http://www.dieselbombers.com/diesel-...ld-thread.html
http://www.dieselbombers.com/diesel-...ld-thread.html
Fab is going to be required for the engine mounts, and you'll have to figure out track bar clearance as the OM617 is a front-sump design. Overall it's the most practical choice for an XJ. No reinforcements required, similar power curve, similar weight. Nowhere near as in-depth as a Cummins or VW engine.
I've a ton of research with regards to a TDI or Mercedes diesel swap. My vision had noting to do with Hp/torque. I wanted fuel economy and the ability to make my own fuel.
Believe it or not the biggest hurdle for me was getting the DMV to sign off of it, second was the weight and size of most of the economically availible Diesel engines.
Believe it or not the biggest hurdle for me was getting the DMV to sign off of it, second was the weight and size of most of the economically availible Diesel engines.
Last edited by salad; Nov 10, 2014 at 10:54 AM.
CF Veteran
Joined: Mar 2012
Posts: 1,369
Likes: 0
From: Richmond, VA
Model: Cherokee
OM617 may be old, but you'll pay out the *** for one for a reason. They're as reliable as a 4.0, they're not overly tall, they run forever (some of our Sprinters at work with them have 700k+ miles on them) and they put out a TON of low end torque. They will fit in a 4.0 engine bay and there's a couple companies out there that make conversion kits for them specifically for XJs as well as other Jeeps.
No ones swapping them in just to do a diesel, they're swapping them in because they're ideal for offroad use in a Jeep because of how much low end torque they put out.
As for a 4BT, it's a waste of time and money in an XJ. It's been done, but they're very tall and require substantial modification of the engine bay, suspension, and steering to accommodate the size.
No ones swapping them in just to do a diesel, they're swapping them in because they're ideal for offroad use in a Jeep because of how much low end torque they put out.
As for a 4BT, it's a waste of time and money in an XJ. It's been done, but they're very tall and require substantial modification of the engine bay, suspension, and steering to accommodate the size.
CF Veteran
Joined: Jan 2013
Posts: 19,219
Likes: 45
From: west chester, pa
Year: 1999
Engine: 4.0
One thing most people don't think about doing the om617 is that u may need to regear the axles one ratio lower than stock if u are gonna run stock tires. That ll also put the powerband back in the range.
The guys from Carlisle, PA who pioneered the swap has already made adapter plates for all kinds of trans u want to mate it with the 617. They were prototyping the engine mounts also.
To do the swap, u ll need to do either at least 3 inch lift or modify the oil pan because it's a front sump design.
There's a few more tidbits that I probably forgot.
617 swap is in my future plans as well. As soon as the 4.0 behind my ax15 blow up.
The guys from Carlisle, PA who pioneered the swap has already made adapter plates for all kinds of trans u want to mate it with the 617. They were prototyping the engine mounts also.
To do the swap, u ll need to do either at least 3 inch lift or modify the oil pan because it's a front sump design.
There's a few more tidbits that I probably forgot.
617 swap is in my future plans as well. As soon as the 4.0 behind my ax15 blow up.
Senior Member
Joined: May 2014
Posts: 672
Likes: 5
From: Colorado
Year: 2001, 1997
Model: Cherokee
Engine: 4.0L
OM617 engines are bulletproof and you can even put the head bolts on with an impact with no ill effects. 
However, making your own fuel without paying taxes may be illegal and if the fuel is not properly made you can gum up and destroy the injection pump. On the plus side they are entirely mechanical. If your battery is dead you can even push start them. The valves require periodic adjustment. There are no hydraulic lifters.
However, making your own fuel without paying taxes may be illegal and if the fuel is not properly made you can gum up and destroy the injection pump. On the plus side they are entirely mechanical. If your battery is dead you can even push start them. The valves require periodic adjustment. There are no hydraulic lifters.
CF Veteran
Joined: Dec 2011
Posts: 3,643
Likes: 1
They have great torque. For certain. And pull much better than gas regardless of what people may think about torque numbers.
but as said they are heavy motors. I would never even consider one unless I could get the small euro version or similar.
CF Veteran
Joined: Aug 2011
Posts: 3,648
Likes: 4
Model: Cherokee
I have personally driven just about every single newer diesel truck made. I was surprised how crappy their fuel economy is. Maybe your friend has 1 in 10000 that gets 19mpg pulling a heavy trailer. I can assure you most get from 11 - 14 if they are lucky. Still better than gas mind you.
They have great torque. For certain. And pull much better than gas regardless of what people may think about torque numbers.
but as said they are heavy motors. I would never even consider one unless I could get the small euro version or similar.
Senior Member
Joined: Jan 2011
Posts: 842
Likes: 6
From: Escalon, Ca
Year: 1996
Model: Cherokee
Engine: 4litre
Everybody I know has a super duty or a cummins with a programmer. In fuel saving mode they can get fantastic gas milage when driven conservatively.
And no I haven't done the swap, it's would be very challenging to make it smog legal in California. That's my major setback
And no I haven't done the swap, it's would be very challenging to make it smog legal in California. That's my major setback
CF Veteran
Joined: Dec 2011
Posts: 3,643
Likes: 1
Everybody I know has a super duty or a cummins with a programmer. In fuel saving mode they can get fantastic gas milage when driven conservatively.
And no I haven't done the swap, it's would be very challenging to make it smog legal in California. That's my major setback
And no I haven't done the swap, it's would be very challenging to make it smog legal in California. That's my major setback
Senior Member
Joined: Jan 2011
Posts: 842
Likes: 6
From: Escalon, Ca
Year: 1996
Model: Cherokee
Engine: 4litre
CF Veteran
Joined: Dec 2011
Posts: 1,777
Likes: 22
From: PA KOTUFU!
Year: 1998
Engine: 4.0L 162,000
My '85 XJ Diesel with factory 2.1 turbo diesel 5 speed is averaging 32-35mpg. It doesn't matter if around town or highway. With it's 32 gallon fuel tank, 1000 miles are possible on a single fill-up.