Jeep Cherokee Diesel Swap Overview | Mercedes OM617 Conversion

Published on July 19, 2019
Duration: 42:53

This guide details the complex process of swapping a Mercedes OM617 5-cylinder turbo diesel engine into a Jeep Cherokee XJ, as explained by KeystoneCarry. The build emphasizes custom fabrication for motor mounts, intercooler piping, and auxiliary systems, aiming to retain factory functions. It highlights significant technical challenges, including engine failures and clearance issues, and estimates a cost of $6,000-$7,000.

Quick Summary

The Jeep Cherokee XJ OM617 diesel swap by KeystoneCarry is a complex modification costing $6,000-$7,000. Key upgrades include a Dieselmeken fuel pump and planned Holset HX30W turbo, aiming for significant power gains. Challenges involve oil pan clearance and initial engine failures, but the build achieves 24-27 MPG on 33-inch tires.

Chapters

  1. 00:00Project Introduction
  2. 01:08Engine Swap Process
  3. 03:25Build Overview and Engine Choice
  4. 07:18Technical Challenges and Failures
  5. 09:32Drivetrain and Mounting
  6. 11:19Cooling and Performance Upgrades
  7. 15:25Auxiliary Systems
  8. 20:20Testing and Performance
  9. 23:22Clearance and Cost

Frequently Asked Questions

What are the main challenges of swapping a Mercedes OM617 into a Jeep Cherokee XJ?

Key challenges include the OM617's front-sump oil pan causing clearance issues with the front axle, requiring steering modifications. Additionally, initial engine failures due to faulty oil filter relocation kits highlight the need for meticulous component verification during the build process.

What performance upgrades are discussed for the OM617 diesel in the Jeep XJ?

The build features a Dieselmeken fuel pump with 7.5mm elements for increased horsepower and plans for a Holset HX30W turbocharger. These upgrades aim to significantly boost the OM617's output beyond its stock 125hp rating.

What is the estimated cost and fuel economy for this Jeep XJ diesel conversion?

The estimated cost for this comprehensive OM617 diesel swap into a Jeep Cherokee XJ ranges between $6,000 and $7,000. The vehicle achieves a reported fuel economy of 24 MPG in the city and 26-27 MPG on the highway with 33-inch tires.

Why was the Mercedes OM617 chosen over other diesel engines for the Jeep XJ swap?

The OM617 was selected primarily because its physical dimensions are similar to the stock Jeep 4.0L inline-six, facilitating a better fit within the XJ chassis compared to larger options like the Cummins 4BT. It also offers desirable diesel characteristics.

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