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Om606 conversion
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Posted 8/11/2016 1:12 PM
hummermaniac88
Member


Date registered: May 2014
Location: Montreal, Canada
Vehicle(s): 1997 Mercedes G320 LWB (Japanases Market)
Posts: 39
25
Om606 conversion

Greetings guys,

I'm currently doing a om606 engine swap with a 766.2 into my 1997 g320 with a m104 and a 766.3.

I have a few questions regarding wiring.

For those who has gone through this, how did you hook up the glow plug wiring?

As for the fuel tank, did you guys swap a w463 diesel tank? Or simply used an external fuel pump on the original tank and modified the fuel lines to fit?

Thanks in advance



#233333
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Posted 8/11/2016 2:00 PM
AlanMcR
Expert




Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
2000
RE: Om606 conversion

Caveat, I haven't done a conversion, but I have the factory setup.  This of course uses the diesel tank.  The pickup in that tank is just a tube to the bottom with a plastic sieve at the end.  In practice, the sieve is too fine and can be plugged with algae & crud.  I replaced the sock with a coarse stainless screen with openings about half of the inner diameter of the tube.  Actual pre-filtering is accomplished with a washable screen that is mounted just ahead of the tank.  The lift pump (on the side of the injection pump) and filtering does the rest. I would think that all of this could be duplicated with the gasoline tank.

#233335 - in reply to #233333
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Posted 8/11/2016 2:51 PM
hummermaniac88
Member


Date registered: May 2014
Location: Montreal, Canada
Vehicle(s): 1997 Mercedes G320 LWB (Japanases Market)
Posts: 39
25
RE: Om606 conversion

AlanMcR - 8/11/2016 2:00 PM

Caveat, I haven't done a conversion, but I have the factory setup.  This of course uses the diesel tank.  The pickup in that tank is just a tube to the bottom with a plastic sieve at the end.  In practice, the sieve is too fine and can be plugged with algae & crud.  I replaced the sock with a coarse stainless screen with openings about half of the inner diameter of the tube.  Actual pre-filtering is accomplished with a washable screen that is mounted just ahead of the tank.  The lift pump (on the side of the injection pump) and filtering does the rest. I would think that all of this could be duplicated with the gasoline tank.



Thanks Alan, my mechanic suggest the same with universal equipment for the float, pump and filter all keeping the oem tank.
#233336 - in reply to #233335
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Posted 8/11/2016 7:26 PM
Titus Pullo
Elite Veteran




Date registered: May 2007
Location: Ottawa, ON, Canada
Vehicle(s): '90 Wolf 240GD, '06 G270 CDI.
Posts: 1010
1000
RE: Om606 conversion

hummermaniac88 - 8/11/2016 1:12 PM Greetings guys, I'm currently doing a om606 engine swap with a 766.2 into my 1997 g320 with a m104 and a 766.3. I have a few questions regarding wiring. For those who has gone through this, how did you hook up the glow plug wiring? As for the fuel tank, did you guys swap a w463 diesel tank? Or simply used an external fuel pump on the original tank and modified the fuel lines to fit? Thanks in advance
I used a glow plugs relay of 603 engine - the wiring is as simple as it gets. For the fuel tank - I used the original tank, removed the gas injection pump and just hooked up the fuel line, you dont need a electric pick up pump.
#233361 - in reply to #233333
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Posted 8/11/2016 8:38 PM
hummermaniac88
Member


Date registered: May 2014
Location: Montreal, Canada
Vehicle(s): 1997 Mercedes G320 LWB (Japanases Market)
Posts: 39
25
RE: Om606 conversion

Titus Pullo - 8/11/2016 7:26 PM

hummermaniac88 - 8/11/2016 1:12 PM Greetings guys, I'm currently doing a om606 engine swap with a 766.2 into my 1997 g320 with a m104 and a 766.3. I have a few questions regarding wiring. For those who has gone through this, how did you hook up the glow plug wiring? As for the fuel tank, did you guys swap a w463 diesel tank? Or simply used an external fuel pump on the original tank and modified the fuel lines to fit? Thanks in advance
I used a glow plugs relay of 603 engine - the wiring is as simple as it gets. For the fuel tank - I used the original tank, removed the gas injection pump and just hooked up the fuel line, you dont need a electric pick up pump.


Ok so you just took the whole 603 Glow Plug relay wiring?

For the fuel tank it sounds very simple, you just used the IP as the pump to pull fuel from the original tank? And you kept the original float for the fuel gauge?

Titus, since you have done this before, anything else I should be aware of as for adapting a M104 based w463 to an OM606?
#233365 - in reply to #233361
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Posted 8/11/2016 8:56 PM
Titus Pullo
Elite Veteran




Date registered: May 2007
Location: Ottawa, ON, Canada
Vehicle(s): '90 Wolf 240GD, '06 G270 CDI.
Posts: 1010
1000
Re: Om606 conversion

Yes,the IP has quite good pickup pump built into it.
Yes I used a 603 glow plugs relay and harness. after this you have to wire only 4 wires - power from the ignition key, ground, wire to the dash light and wire from the temp. sensor to the relay.
I hate tiping, call me if you have any questions 6132633470
#233366 - in reply to #233333
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Posted 8/12/2016 9:48 AM
petermerle
Expert




Date registered: Apr 2006
Location: Cape Town ( deep south )
Vehicle(s): W460 *1, W123 *2, W124
Posts: 1315
1000
Re: Om606 conversion

What Ip have you got on the OM606 - the original electronic or did you fit mechanical one from OM603
#233377 - in reply to #233333
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Posted 8/13/2016 4:38 PM
diesel_jim
Veteran




Date registered: Jan 2014
Location: N Wiltshire. UK
Vehicle(s): LR Defender 110, 1989 W460 SWB
Posts: 114
100
Re: Om606 conversion

I used the glowplug loom from a landrover discovery/defender 300Tdi.. the whole relay and harness.

Similar to the early MB models I think... only needs ignition, battery and warning light connecting up.
#233393 - in reply to #233333
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Posted 8/18/2016 12:04 PM
hummermaniac88
Member


Date registered: May 2014
Location: Montreal, Canada
Vehicle(s): 1997 Mercedes G320 LWB (Japanases Market)
Posts: 39
25
RE: Om606 conversion

Thanks for the info guys!

I do have the om603 pump.


Here's another puzzle. Do I remove these AC lines? My donor car for the om606 (e300) has a different ac system. How do I hook it up?



(mms_img1312756934.jpg)



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#233490 - in reply to #233333
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Posted 9/15/2016 7:26 PM
hummermaniac88
Member


Date registered: May 2014
Location: Montreal, Canada
Vehicle(s): 1997 Mercedes G320 LWB (Japanases Market)
Posts: 39
25
RE: Om606 conversion

Wondering if any of you guys have experience with the horizontal alda kit from DPUK. Having trouble figuring how to install the parts.

Luke sent me a picture of the top part which is straight forward. I'm wondering about the bottom part.

#233876 - in reply to #233333
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Posted 9/15/2016 7:27 PM
hummermaniac88
Member


Date registered: May 2014
Location: Montreal, Canada
Vehicle(s): 1997 Mercedes G320 LWB (Japanases Market)
Posts: 39
25
RE: Om606 conversion

Here are the parts.



(2016-09-15 19.35.31.png)



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#233877 - in reply to #233333
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Posted 9/15/2016 7:36 PM
hummermaniac88
Member


Date registered: May 2014
Location: Montreal, Canada
Vehicle(s): 1997 Mercedes G320 LWB (Japanases Market)
Posts: 39
25
RE: Om606 conversion

Can anyone identify these parts for me? And the wire in the last picture.




(2016-09-15 19.33.40.jpg)



(2016-09-15 19.33.09.jpg)



(2016-09-15 19.32.45.jpg)



(2016-09-15 19.32.10.jpg)



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Attachments 2016-09-15 19.33.40.jpg (410KB - 1 downloads)
Attachments 2016-09-15 19.33.09.jpg (376KB - 0 downloads)
Attachments 2016-09-15 19.32.45.jpg (407KB - 0 downloads)
Attachments 2016-09-15 19.32.10.jpg (406KB - 0 downloads)
#233878 - in reply to #233333
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Posted 9/16/2016 12:31 AM
ILIAN
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Date registered: Sep 2014
Location: Boston MA
Vehicle(s): 2000 G500 1999 CL500
Posts: 181
100
Re: Om606 conversion

Picture 1 is a coolant pump used to increase flow thru the heater core when you turn on the heat. Picture 2 is a vacuum valve for one of the lockers (I think transfer case lock). The wire on the last picture is for the heated windshield washer nozzles I think.
#233880 - in reply to #233876
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Posted 9/16/2016 9:50 AM
hummermaniac88
Member


Date registered: May 2014
Location: Montreal, Canada
Vehicle(s): 1997 Mercedes G320 LWB (Japanases Market)
Posts: 39
25
Re: Om606 conversion

Thanks for the answers, onward with the project!
#233882 - in reply to #233333
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Posted 9/16/2016 12:42 PM
hummermaniac88
Member


Date registered: May 2014
Location: Montreal, Canada
Vehicle(s): 1997 Mercedes G320 LWB (Japanases Market)
Posts: 39
25
Re: Om606 conversion

Guys where do I plug in the rpm sensor and temp sensor?
#233883 - in reply to #233333
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Posted 9/25/2017 4:45 AM
Indo_G
Member


Date registered: Jan 2007
Location: Jakarta, Indonesia
Vehicle(s): '96 W463 300GE OM606 722.6 conversion
Posts: 42
25
Re: Om606 conversion

Hi, i'm doing the same conversion from DPUK at the moment. How do you solve the RPM issue?
#237216 - in reply to #233883
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Posted 9/27/2017 5:21 PM
Loki Laufeyjarson



Date registered: Apr 2006
Location: 66°N, 19°W
Vehicle(s):
500
Re: Om606 conversion

http://pointedthree.com/disc/forums/showthread.php?tid=23282&posts=...
#237228 - in reply to #237216
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