Jeep Cherokee Diesel Swap Overview | Mercedes OM617 Conversion

Published on July 19, 2019
Duration: 42:53

This Jeep Cherokee XJ conversion features a Mercedes OM617 turbo diesel engine swap, chosen for its similar size to the stock 4.0L and diesel efficiency. The build details significant mechanical challenges, including engine failures and custom fabrication for drivetrain, cooling, and auxiliary systems. Despite an estimated cost of $6,000-$7,000, the project successfully retains factory functions and achieves 24-27 MPG.

Quick Summary

The Mercedes OM617 turbo diesel engine was chosen for a Jeep Cherokee XJ conversion due to its compact size, fitting similarly to the stock 4.0L. This build faced challenges like engine seizure and required custom fabrication for mounts and cooling, costing an estimated $6,000-$7,000.

Chapters

  1. 00:00Project Introduction: Diesel XJ Build
  2. 01:08Engine Swap Process: OM617 Installation
  3. 03:25Build Overview & Engine Choice: OM617 vs Others
  4. 07:18Technical Challenges: Engine Failures & Rebuild
  5. 09:32Drivetrain: AX15 Transmission & Custom Mounts
  6. 11:19Cooling & Performance: Intercooler & Fuel Pump
  7. 15:25Auxiliary Systems: AC, Vacuum & Power Steering
  8. 20:20Testing & Performance: Idle, Driving & MPG
  9. 23:22Clearance Issues & Total Build Cost

Frequently Asked Questions

Why choose a Mercedes OM617 engine for a Jeep Cherokee XJ diesel swap?

The Mercedes OM617 turbo diesel was chosen because it fits similarly to the stock 4.0L inline-six engine, offering the benefits of diesel power and efficiency without requiring excessive chassis modification.

What were the main technical challenges during the Jeep XJ diesel conversion?

Key challenges included two engine seizures due to faulty oil filter relocation kit diagrams, requiring a full rebuild. Custom fabrication was also needed for motor mounts, intercooler piping, and adapting auxiliary systems like AC and vacuum.

How does the OM617 engine perform in the Jeep Cherokee XJ?

The converted Jeep demonstrates smooth idle, good drivability, and audible turbo spool. Fuel economy is reported at 24 MPG city and 26-27 MPG highway on 33-inch tires.

What is the estimated cost for a Jeep Cherokee XJ Mercedes OM617 diesel swap?

The total estimated cost for this comprehensive build ranges between $6,000 and $7,000, highlighting that it is a complex and expensive project, not a simple bolt-in modification.

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