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Mercedes OM617 Powered 110 Build Up

134138 Views 400 Replies 55 Participants Last post by  Ephry73
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The starting vehicle:
1986 110 with 2.5 liter Petrol engine, leaking fuel tank, and interior and under hood area covered in carpet and other sound deadening material.

Purchased from a UK dealer. It was used by DRA for flight testing of countermeasures equipment. Unique in that it had 44,500 miles and was without front vents presumably to cut down on noise and interference.

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I still have to go thru the bag of bolts but I so have everything save for one on the pans. I am excited to get my frame so I can start bolting things on.

Quick question: the new pans have more, less or the same oil capacity? They look great in the pix.
I still have to go thru the bag of bolts but I so have everything save for one on the pans. I am excited to get my frame so I can start bolting things on.

Quick question: the new pans have more, less or the same oil capacity? They look great in the pix.
They have more oil capacity... anything worth doing is worth overdoing.
They have more oil capacity... anything worth doing is worth overdoing.
Nice to hear - I like your way of thinking, haha
"SMac" stopped by on his way through the area and drove the Mercedes 110.
He provided lots of positive feedback.
Test drives available at MAR and Uwharrie if all goes well with my leave schedule.
I could have spent a full day roaming around Robert's place! Rovers and diesels everywhere. Great meeting you Robert and that OM617 is somethin.
Nice to see a nice kit out there!! I really like my OM617 in my 109 . Building a 110 next and am on the fence of what power plant to go with. But I'm liking what I see here.
Nice to see a nice kit out there!! I really like my OM617 in my 109 . Building a 110 next and am on the fence of what power plant to go with. But I'm liking what I see here.
Thanks... It was a lot of work to design, prototype, and manufacture... worth every minute and penny spent!

Kits are starting to sell and as soon as people have them up and running and others get a chance to see them and drive them, they should be very popular.

Have been so busy have not had much time to play around with the tuning.
We did install a boost bleed off valve to bring the boost up to about 12 - 14 bar on the scale, but it increased the engine temperature when above 75 MPH in the hot summer, so we took it out and the boost stays at 9 bar max and the higher temperatures are no longer an issue.
This is probably a non-issue where you are in Alaska.

Sometime in the future want to install a larger intercooler as we have the small 300TDI intercooler at present. As you can see in the pictures, there is loads of room up front to mount a thicker radiator, larger oil cooler, and larger intercooler.

Also want to use a variable vane style turbo to get more boost at low RPM.
This will improve the off road performance which is not bad, but could always be better.

The thing that is so impressive regarding the OM617 is how smooth it is.
The faster it revs the smoother it gets.
It's the best running small diesel I have ever encountered.

With all the hooey lately regarding imports, the OM617 engine is completely federalized and 100% legit, legal, and so on.
The OM617 engines can be had at pick-n-pull for about $300 and were imported by the hundreds of thousands in North America.
Since they rarely go bad, the OM617 is relatively easy to find in good used condition at bargain prices.
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Ed:
Forgot to ask, did you do any fine IP tuning?
Ed:
Forgot to ask, did you do any fine IP tuning?
Richard

I did remove the alda and and turned the fuel up just a bit using OM606s procedure from the STD forum. I timed the pump using the drip procedure and am running 14 psi of boost . I ran 15 k miles on my last trip with the boost at 10 psi as I have no intercooler. And still walked away from a D110 from this board running a TDI on the hills. :)
Typos - put in bar instead of PSI

We did install a boost bleed off valve to bring the boost up to about 12 - 14 bar on the scale, but it increased the engine temperature when above 75 MPH in the hot summer, so we took it out and the boost stays at 9 bar max and the higher temperatures are no longer an issue.
Should have read:

We did install a boost bleed off valve to bring the boost up to about 12 - 14 PSI on the scale, but it increased the engine temperature when above 75 MPH in the hot summer, so we took it out and the boost stays at 9 PSI max and the higher temperatures are no longer an issue...
I still have to go thru the bag of bolts but I so have everything save for one on the pans. I am excited to get my frame so I can start bolting things on.

Quick question: the new pans have more, less or the same oil capacity? They look great in the pix.
Pan shipped last week.
Kits are sold out with the second batch available in Jan/Feb 2014.
We have not tuned our engine much, but here is an interesting thread:

http://www.superturbodiesel.com/std/Thread-OM617-convert-from-MW-to-M-pump
Weren't you at one time thinking about developing a hydraulic-style mount for the 200 and 300 tdi's?
Yes making custom mounts for the 200 and 300TDI are on the list, but am too backed up with work to get to them.
Yes making custom mounts for the 200 and 300TDI are on the list, but am too backed up with work to get to them.
Would this be the Mercedes hydraulic mounts fitted to a 200/300tdi?
What are the part #'s for those mounts?
If I were to make a custom motor mount for the Land Rover TDI, it would be using Mercedes mount: 2012403917.
Currently discussing buying an M-Series IP for the OM617 that will yield some decent low end torque and 160 - 165 HP.
Robert,

I just found out what this year's tax refund is going to be....

What does your current stock of kits look like. Any manufacturing runs planned this year? -Dave
Robert,

I just found out what this year's tax refund is going to be....

What does your current stock of kits look like. Any manufacturing runs planned this year? -Dave
We have 1 defender kit in stock that I was saving to replace the 200TDI in our 1983 110, but it is available now because by the time I clear all the other projects out of the way, the second production run will be completed.
Was also saving it to have parts in case someone installing a kit made a major mistake and broke something.

In other words, we have one left if you need it.

Can't wait to install that new IP and have 40 more HP and lots more torque.
Won't know the numbers exactly, but am hoping for 220 lbft of torque with 160 HP.
The stock IPs are tuned to prevent the engine from putting out any smoke.
Was behind a 300D sedan last week on the interstate and you could net tell it was a diesel.
It smoked a lot less than the 200TDI.
With the new settings it will definitely put out more smoke, but not an unacceptable amount.
Ok thanks for the info - I will be back in the states later in February and will be in touch regardless. I've got your e-mail from previous conversations.

Are you going to be at Uwharrie Safari in April?
Can't wait to install that new IP and have 40 more HP and lots more torque. Won't know the numbers exactly, but am hoping for 220 lbft of torque with 160 HP. The stock IPs are tuned to prevent the engine from putting out any smoke. Was behind a 300D sedan last week on the interstate and you could net tell it was a diesel. It smoked a lot less than the 200TDI. With the new settings it will definitely put out more smoke, but not an unacceptable amount.
I will definitely be interested in seeing how the new IP does. 40HP is not bad at all. What is the cost on the IP?
Hello Richard
I have a custom, precision, computer-aided, metal fabrication company that could help you with the mounts, or anything else, if that's of any benefit to you.
Regards
Jack
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