STD Other Projects Beach Roamer Resurrection - CJ7 OM617 repower

Beach Roamer Resurrection - CJ7 OM617 repower

Beach Roamer Resurrection - CJ7 OM617 repower

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turbojeep
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81
03-16-2015, 10:11 PM #1
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Back for 2000, we picked up a 1985 CJ7 with a 258 I6, T-5 transmission with a Dana 300 transfercase. We took it everywhere, out to West Texas, the beach, Houston and everywhere in between. It was great except that on anything other than a flat road with a 30mph tail wind, 5th gear was a total waste. That, and it got 8mpg on a good day. Found out that we had a dying cylinder in 2006, so we pulled it into the garage and started taking the engine apart and laid everything out and organized on a 1"x12"x8' board. One night, after we had pulled the pistons, some of the things we had hanging from the garage door rails crashed to the floor and catapulted pistons, pins, bolts and lord knows what else all over the garage floor. Effectively killing all momentum on the engine rebuild and turning the jeep into shelving.  


In 2013, When I bought my 300D, it came with a free spare motor from a wrecked 1983 wagon. Supposedly only 150K miles, but no real way to be able to test that. It had been sitting for 3+ years in the dude's backyard, covered by once was a tarp. Everything seemed to be in pretty fair condition and he said that they had drained all fluids before he put it back there. Long story short, bought the car and moved the engine to the garage. The plan was to swap the OM617 into the Jeep and get it back on its feet, this time with more torque, a little less HP and double the MPG. 


Engine after cleanup and deleafing

[Image: 16432170942_d0fe817d03_b.jpg]
[Image: 16245703170_bfc7ff8117_b.jpg]



I really didn't get after the swap until May of 2014, a couple months before my wedding. Knowing that whatever free time I had was quickly going to be in other things.  Pulled the short block out of the Jeep and started getting everything moved over. 

Test mated the transmission for clearancing 

[Image: 16840074075_50b59e0537_b.jpg]

The adapter kit is from MercedesDiesel4x4, great kit. Had everything that we needed and the instructions were pretty clear. Hardest part of the whole thing was finding a place that would balance the flywheels to each other. After getting sloughed off to several different shops, an old timer that looked at it said that he didn't see any extra weights on it and that it looked to be neutral balanced like the original Jeep FW was. So we just ran it as is, no special balancing done.   

*Crappy phone pics to follow* 

[Image: 16246856809_1a8d59a333_b.jpg]

[Image: 16245447498_3d0de8edf1_b.jpg]

[Image: 16245703760_5e689523e2_b.jpg]

Actually fits in there really well. With the fan on there, it was a hair longer than the old engine. But without the fan, they were about the same length, even with the adapter plate installed. In the end we kept the stock Jeep radiator (which is slightly larger than the Benz original) and switching to a Ford Taurus electric ran, for rad hose routing reasons. 
This post was last modified: 03-17-2015, 06:22 PM by turbojeep.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
03-16-2015, 10:11 PM #1

Back for 2000, we picked up a 1985 CJ7 with a 258 I6, T-5 transmission with a Dana 300 transfercase. We took it everywhere, out to West Texas, the beach, Houston and everywhere in between. It was great except that on anything other than a flat road with a 30mph tail wind, 5th gear was a total waste. That, and it got 8mpg on a good day. Found out that we had a dying cylinder in 2006, so we pulled it into the garage and started taking the engine apart and laid everything out and organized on a 1"x12"x8' board. One night, after we had pulled the pistons, some of the things we had hanging from the garage door rails crashed to the floor and catapulted pistons, pins, bolts and lord knows what else all over the garage floor. Effectively killing all momentum on the engine rebuild and turning the jeep into shelving.  


In 2013, When I bought my 300D, it came with a free spare motor from a wrecked 1983 wagon. Supposedly only 150K miles, but no real way to be able to test that. It had been sitting for 3+ years in the dude's backyard, covered by once was a tarp. Everything seemed to be in pretty fair condition and he said that they had drained all fluids before he put it back there. Long story short, bought the car and moved the engine to the garage. The plan was to swap the OM617 into the Jeep and get it back on its feet, this time with more torque, a little less HP and double the MPG. 


Engine after cleanup and deleafing

[Image: 16432170942_d0fe817d03_b.jpg]
[Image: 16245703170_bfc7ff8117_b.jpg]



I really didn't get after the swap until May of 2014, a couple months before my wedding. Knowing that whatever free time I had was quickly going to be in other things.  Pulled the short block out of the Jeep and started getting everything moved over. 

Test mated the transmission for clearancing 

[Image: 16840074075_50b59e0537_b.jpg]

The adapter kit is from MercedesDiesel4x4, great kit. Had everything that we needed and the instructions were pretty clear. Hardest part of the whole thing was finding a place that would balance the flywheels to each other. After getting sloughed off to several different shops, an old timer that looked at it said that he didn't see any extra weights on it and that it looked to be neutral balanced like the original Jeep FW was. So we just ran it as is, no special balancing done.   

*Crappy phone pics to follow* 

[Image: 16246856809_1a8d59a333_b.jpg]

[Image: 16245447498_3d0de8edf1_b.jpg]

[Image: 16245703760_5e689523e2_b.jpg]

Actually fits in there really well. With the fan on there, it was a hair longer than the old engine. But without the fan, they were about the same length, even with the adapter plate installed. In the end we kept the stock Jeep radiator (which is slightly larger than the Benz original) and switching to a Ford Taurus electric ran, for rad hose routing reasons. 

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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turbojeep
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81
03-16-2015, 10:23 PM #2
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After we got the engine situated about where we wanted it, we saw that the oil pan was slightly resting on the front diff. I had read about this problem and figured that we would just cross that bridge when I made it that far. The solution was to install a lift, went with a Rough Country 5" lift. 

[Image: 16245448188_d9b1f45833_b.jpg]

New ride height, sans engine. I thought it was going to hunker down some when the weight of the engine was on it, but no. I swear it dropped less than .5". 

After that it was just bolting the engine in where we wanted it and sending it home. I was surprised to find that the stock motor mount holes in the frame lined up 90% to where we wanted the mounts on this engine. 

Got it started for the first time



Then about a week later was able to have it roll out of the garage for the first time in 8 years. 
This post was last modified: 03-17-2015, 06:22 PM by turbojeep.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
03-16-2015, 10:23 PM #2

After we got the engine situated about where we wanted it, we saw that the oil pan was slightly resting on the front diff. I had read about this problem and figured that we would just cross that bridge when I made it that far. The solution was to install a lift, went with a Rough Country 5" lift. 

[Image: 16245448188_d9b1f45833_b.jpg]

New ride height, sans engine. I thought it was going to hunker down some when the weight of the engine was on it, but no. I swear it dropped less than .5". 

After that it was just bolting the engine in where we wanted it and sending it home. I was surprised to find that the stock motor mount holes in the frame lined up 90% to where we wanted the mounts on this engine. 

Got it started for the first time



Then about a week later was able to have it roll out of the garage for the first time in 8 years. 

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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turbojeep
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Off roading luxury sedans

81
03-17-2015, 10:43 PM #3
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Jeep on her maiden voyage around the neighborhood. 

[Image: 16433109015_8390106f56_c.jpg]


[Image: 15810571784_5038f04d13_b.jpg]

[Image: 15460228448_8a883ca436_c.jpg]

Early October 

All in all, the jeep did great. Biggest issue at that point was not having any kind of throttle return. For some reason it would rev like no other, practically instantaneously. Not reassuring to drive like that long term though. 

At this point I still had thing to button up:

- Throttle linkage
- Wire alternator
- Install oil gauge
- Buy locking hubs (driver side busted on the last trip we took it on in 2006)
- Change oil
- Engine temp gauge
- EGT gauge
- Shutoff valve
- Hook up fuel tank
- Get it registered
- Unstick siezed oil dipstick
This post was last modified: 03-22-2015, 06:08 PM by turbojeep.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
03-17-2015, 10:43 PM #3

Jeep on her maiden voyage around the neighborhood. 

[Image: 16433109015_8390106f56_c.jpg]


[Image: 15810571784_5038f04d13_b.jpg]

[Image: 15460228448_8a883ca436_c.jpg]

Early October 

All in all, the jeep did great. Biggest issue at that point was not having any kind of throttle return. For some reason it would rev like no other, practically instantaneously. Not reassuring to drive like that long term though. 

At this point I still had thing to button up:

- Throttle linkage
- Wire alternator
- Install oil gauge
- Buy locking hubs (driver side busted on the last trip we took it on in 2006)
- Change oil
- Engine temp gauge
- EGT gauge
- Shutoff valve
- Hook up fuel tank
- Get it registered
- Unstick siezed oil dipstick

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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turbojeep
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81
03-17-2015, 11:20 PM #4
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We moved down to The Valley and brought the Jeep down in November. The school has a nice shop and was a huge benefit to being here. I was able to knock out a lot of the list that I had from October, while at the same time making more work for myself. 

Got it registered!

[Image: 15026207583_e7766922d5_c.jpg]

Pulled the ALDA

[Image: 15417313698_3b00f3bdc1_c.jpg]

Upgraded from the old Warn (plastic) hubs to Mile Markers (BEEF)

[Image: 16433080625_8d925c0e8d_c.jpg]

Took it out on the road and had top speed of about 65mph... Found out that it still had the stock 3.31 gears, regeared to 4.88s. Should put me just a little deeper than stock MB gearing in 5th.

 [Image: 16501004561_7aa7041afb_c.jpg]

While I was in there, took the opportunity to slap in an auto locker in the front end

[Image: 15810566334_5702738c7e_c.jpg]

Had to test it out

[Image: 15810593214_639377d6dd_c.jpg]

The lower gearing made a huge differance down low, blast to bomb around town in

[Image: 15579893516_1325fa7c40_c.jpg]

Connected the fuel tank and got it inspected

[Image: 15816535854_1f4ab30dff_c.jpg]

Drove it around and thought I was overheating it.... still have a max speed of ~65mph....

[Image: 15813023143_25c0784bd5_c.jpg]

False alarm, but I thought for sure I fried it at the time. 

MARCH 5th & 6th

Got most of the bugs out of it and trailered it up to my parent's place so they could have second car. Then started having a problems of shutting off after about 5 miles worth of driving. Prefilter was getting clogged from tank debris so we dropped it last weekend. This is what we found:

Two week old diesel

[Image: 16228125374_72cc9bcc7f_c.jpg]

 Sender unit and screen

[Image: 16643179937_58aacf1cd4_c.jpg]

Screen close up

[Image: 16664355059_bcd56e0625_c.jpg]

We thought we had found our problem, so we clean the tank and put it all back together

Also installed pyro gauge

[Image: 16230526333_1fd99bf42d_c.jpg]

Used a shopvac shoved up the down pipe to help pull shavings. Seems to have worked, turbo is still functional

[Image: 16662896688_e42ec020f5_c.jpg]
This post was last modified: 03-22-2015, 06:24 PM by turbojeep.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
03-17-2015, 11:20 PM #4

We moved down to The Valley and brought the Jeep down in November. The school has a nice shop and was a huge benefit to being here. I was able to knock out a lot of the list that I had from October, while at the same time making more work for myself. 

Got it registered!

[Image: 15026207583_e7766922d5_c.jpg]

Pulled the ALDA

[Image: 15417313698_3b00f3bdc1_c.jpg]

Upgraded from the old Warn (plastic) hubs to Mile Markers (BEEF)

[Image: 16433080625_8d925c0e8d_c.jpg]

Took it out on the road and had top speed of about 65mph... Found out that it still had the stock 3.31 gears, regeared to 4.88s. Should put me just a little deeper than stock MB gearing in 5th.

 [Image: 16501004561_7aa7041afb_c.jpg]

While I was in there, took the opportunity to slap in an auto locker in the front end

[Image: 15810566334_5702738c7e_c.jpg]

Had to test it out

[Image: 15810593214_639377d6dd_c.jpg]

The lower gearing made a huge differance down low, blast to bomb around town in

[Image: 15579893516_1325fa7c40_c.jpg]

Connected the fuel tank and got it inspected

[Image: 15816535854_1f4ab30dff_c.jpg]

Drove it around and thought I was overheating it.... still have a max speed of ~65mph....

[Image: 15813023143_25c0784bd5_c.jpg]

False alarm, but I thought for sure I fried it at the time. 

MARCH 5th & 6th

Got most of the bugs out of it and trailered it up to my parent's place so they could have second car. Then started having a problems of shutting off after about 5 miles worth of driving. Prefilter was getting clogged from tank debris so we dropped it last weekend. This is what we found:

Two week old diesel

[Image: 16228125374_72cc9bcc7f_c.jpg]

 Sender unit and screen

[Image: 16643179937_58aacf1cd4_c.jpg]

Screen close up

[Image: 16664355059_bcd56e0625_c.jpg]

We thought we had found our problem, so we clean the tank and put it all back together

Also installed pyro gauge

[Image: 16230526333_1fd99bf42d_c.jpg]

Used a shopvac shoved up the down pipe to help pull shavings. Seems to have worked, turbo is still functional

[Image: 16662896688_e42ec020f5_c.jpg]

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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turbojeep
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81
03-18-2015, 08:18 AM #5
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Not sure what it going on with my pictures, they show up in the preview... and they first couple of posts are the same format as the rest....

* GOT THE PICTURES FIGURED OUT *
This post was last modified: 03-22-2015, 06:26 PM by turbojeep.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
03-18-2015, 08:18 AM #5

Not sure what it going on with my pictures, they show up in the preview... and they first couple of posts are the same format as the rest....

* GOT THE PICTURES FIGURED OUT *

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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turbojeep
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81
03-18-2015, 08:53 AM #6
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General shots of the engine bay, still need to get all the old wiring pulled and contain the new wires better. It runs, that's the main thing right now.  Big Grin


[Image: 16624835108_8b85f144dc_c.jpg]

Dawes MKII boost controller. I was going to make my one, but sprung for this one. Stupid easy to use and greatly reduced lag getting to peak boost of 13lbs. No spiking or surging. $ well spent. 

[Image: 16811283111_1b391a0683_c.jpg]

The throttle linkage is hooked up to a stock CJ7 I-6 throttle cable. Works pretty smooth surprisingly and get full range of input

[Image: 16190042554_fb6ac29f40_c.jpg]

There was enough room to run the mechanical fan, but since the lower outlet on the radiator was on the wrong side the hose had to cross right through where the fan would have been. 

[Image: 16812380835_f3d7b862a3_c.jpg]

Brake booster line was a hybrid/homegrown setup based off the stock MB vacuum hose 

[Image: 16605098607_fcc1fc7cce_c.jpg]

Oil cooler placement, had custom hoses made from a local hydraulic shop. Came out to be less than $60 for 8ft of hose with fittings. 

[Image: 16786510306_6d3f9f9b28_c.jpg]

Clearance between the oil pan and front diff. Not much flex in the front, so we should be good there.

[Image: 16786508116_3f7d4e403b_c.jpg]
This post was last modified: 03-22-2015, 06:35 PM by turbojeep.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
03-18-2015, 08:53 AM #6

General shots of the engine bay, still need to get all the old wiring pulled and contain the new wires better. It runs, that's the main thing right now.  Big Grin


[Image: 16624835108_8b85f144dc_c.jpg]

Dawes MKII boost controller. I was going to make my one, but sprung for this one. Stupid easy to use and greatly reduced lag getting to peak boost of 13lbs. No spiking or surging. $ well spent. 

[Image: 16811283111_1b391a0683_c.jpg]

The throttle linkage is hooked up to a stock CJ7 I-6 throttle cable. Works pretty smooth surprisingly and get full range of input

[Image: 16190042554_fb6ac29f40_c.jpg]

There was enough room to run the mechanical fan, but since the lower outlet on the radiator was on the wrong side the hose had to cross right through where the fan would have been. 

[Image: 16812380835_f3d7b862a3_c.jpg]

Brake booster line was a hybrid/homegrown setup based off the stock MB vacuum hose 

[Image: 16605098607_fcc1fc7cce_c.jpg]

Oil cooler placement, had custom hoses made from a local hydraulic shop. Came out to be less than $60 for 8ft of hose with fittings. 

[Image: 16786510306_6d3f9f9b28_c.jpg]

Clearance between the oil pan and front diff. Not much flex in the front, so we should be good there.

[Image: 16786508116_3f7d4e403b_c.jpg]

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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turbojeep
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81
03-18-2015, 10:39 AM #7
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Which brings us up to date. After I cleaned the tank, new filters, new tank pick up screen and unobstructed lines; I now have less fuel than it previously had.

After sitting, the prefilter will be about half full with diesel. However, soon as it starts running the filter will drain to the point that it looks empty, even at idle. It will maintain like that for a bit, then after about 20 minutes it will start running rough and then shut off from lack of fuel. 

I haven't run it off a jug yet, but have tried with the tank lid off. No difference. 

Lift pump is suspect at the moment...
This post was last modified: 03-18-2015, 10:53 PM by turbojeep.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
03-18-2015, 10:39 AM #7

Which brings us up to date. After I cleaned the tank, new filters, new tank pick up screen and unobstructed lines; I now have less fuel than it previously had.

After sitting, the prefilter will be about half full with diesel. However, soon as it starts running the filter will drain to the point that it looks empty, even at idle. It will maintain like that for a bit, then after about 20 minutes it will start running rough and then shut off from lack of fuel. 

I haven't run it off a jug yet, but have tried with the tank lid off. No difference. 

Lift pump is suspect at the moment...

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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turbojeep
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81
03-21-2015, 04:08 PM #8
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Had the lift pump taken off for rebuild... Snapped one of the ears off. Now I have to figure out where to get another lift pump.... Great.

[Image: 16692249407_5dbcc2b3d6_c.jpg]
This post was last modified: 03-22-2015, 06:39 PM by turbojeep.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
03-21-2015, 04:08 PM #8

Had the lift pump taken off for rebuild... Snapped one of the ears off. Now I have to figure out where to get another lift pump.... Great.

[Image: 16692249407_5dbcc2b3d6_c.jpg]

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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turbojeep
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81
03-21-2015, 04:39 PM #9
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Got a good deal on one off fleabay, should have me back on the road by next weekend.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
03-21-2015, 04:39 PM #9

Got a good deal on one off fleabay, should have me back on the road by next weekend.

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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turbojeep
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81
04-08-2015, 09:47 PM #10
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Got the lift pump rebuilt and slapped in, seems to flow more fuel but after about 5 miles of driving it starts to get doggy. But not near as bad as it used to. I think the lift pump was on it's way out, just not the main culprit to my problem. Going to drop the tank this weekend and pull the filter screen and crank down on all my hose fittings. Hoping that it's something simple and one of my clamps wasn't tightened all the way. Fingers crossed.
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
04-08-2015, 09:47 PM #10

Got the lift pump rebuilt and slapped in, seems to flow more fuel but after about 5 miles of driving it starts to get doggy. But not near as bad as it used to. I think the lift pump was on it's way out, just not the main culprit to my problem. Going to drop the tank this weekend and pull the filter screen and crank down on all my hose fittings. Hoping that it's something simple and one of my clamps wasn't tightened all the way. Fingers crossed.

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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Hario'
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894
04-09-2015, 03:32 AM #11
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The jeep didn't have an electric fuel pump originally? Reoving the lift pump and fitting a rear mounted electric pump is my suggestion, I've had no end of problems with the vacuum drawn Mercedes fuel sysyems..



Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]
Hario'
04-09-2015, 03:32 AM #11

The jeep didn't have an electric fuel pump originally? Reoving the lift pump and fitting a rear mounted electric pump is my suggestion, I've had no end of problems with the vacuum drawn Mercedes fuel sysyems..




Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

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turbojeep
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81
04-10-2015, 02:14 PM #12
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No, they were still using mechanical pumps with the original engine. Not sure when they switched to electric, probably the TJ models...

I have really thought about it, but I had an electric pump on my Scout II and had to replace it several times a year. On more than one occasion I was stuck because of it and still have a bias against them. If I could get the mechanical pump reliable I would love to keep it, if not I'll have to change over.

Are you running an electric pump? If so, what is the original application of it?
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
04-10-2015, 02:14 PM #12

No, they were still using mechanical pumps with the original engine. Not sure when they switched to electric, probably the TJ models...

I have really thought about it, but I had an electric pump on my Scout II and had to replace it several times a year. On more than one occasion I was stuck because of it and still have a bias against them. If I could get the mechanical pump reliable I would love to keep it, if not I'll have to change over.

Are you running an electric pump? If so, what is the original application of it?

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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DrewGerhan
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If it don't blow black, take it back!

101
02-06-2016, 03:50 PM #13
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How did you make your alternator charge?

I just did the same in my TJ and I've got no tach or charging. I hooked the cam and crank sensor signal wires together thinking that would do it. Also, I hooked up the dark green wire to the alternator field wire as I was told to do so.

Hmmmmmm
1981 300SD 230k miles "Gently Modified" Daily Driver

1999 F-250 7.3L Power Stroke 150k miles "The Usual Mods" Tow Rig

1981 300SD 190k miles "Heavily Modified" Big Grin  GONE
DrewGerhan
02-06-2016, 03:50 PM #13

How did you make your alternator charge?

I just did the same in my TJ and I've got no tach or charging. I hooked the cam and crank sensor signal wires together thinking that would do it. Also, I hooked up the dark green wire to the alternator field wire as I was told to do so.

Hmmmmmm

1981 300SD 230k miles "Gently Modified" Daily Driver

1999 F-250 7.3L Power Stroke 150k miles "The Usual Mods" Tow Rig

1981 300SD 190k miles "Heavily Modified" Big Grin  GONE

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turbojeep
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81
02-07-2016, 05:31 PM #14
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(02-06-2016, 03:50 PM)DrewGerhan How did you make your alternator charge?

I just did the same in my TJ and I've got no tach or charging. I hooked the cam and crank sensor signal wires together thinking that would do it. Also, I hooked up the dark green wire to the alternator field wire as I was told to do so.

Hmmmmmm

I started with the original alternator pigtail, then spliced into the jeep's existing system. It was a while back and I don't remember off hand how I did it exactly.  I do know that I had to put in an excitor light. Does the TJ have one?

I still do not have a tach, saldy. It's in the works but haven't heard from the guy who was supposed to be getting it calibrated for me. 

On a different note, I should have some big updates on the jeep in the next two weeks!
______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 
turbojeep
02-07-2016, 05:31 PM #14

(02-06-2016, 03:50 PM)DrewGerhan How did you make your alternator charge?

I just did the same in my TJ and I've got no tach or charging. I hooked the cam and crank sensor signal wires together thinking that would do it. Also, I hooked up the dark green wire to the alternator field wire as I was told to do so.

Hmmmmmm

I started with the original alternator pigtail, then spliced into the jeep's existing system. It was a while back and I don't remember off hand how I did it exactly.  I do know that I had to put in an excitor light. Does the TJ have one?

I still do not have a tach, saldy. It's in the works but haven't heard from the guy who was supposed to be getting it calibrated for me. 

On a different note, I should have some big updates on the jeep in the next two weeks!

______________________________

'85 300D ~ 381,XXX miles, HD Bilstein shocks, 27.50x8.50x14R General Grabber AT2 tires, 4 E-Code headlight upgrade with 90w/130w bulbs, boost turned up, new timing chain, and injectors. Brought back from the dead and the hell of WVO! SOLD
'85 CJ7 ~ OM617 swap, Taurus electric fan, T5 trans, Dana 300, 4.88 R&P, Mile Marker locking hubs, ALDA removed, MKII hybrid boost controller, Greazzer's upgraded overflow valve,  AMC 20 rear disk brake conversion, Aussie locked with 33's and 5" Rough Country lift. 

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DrewGerhan
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If it don't blow black, take it back!

101
02-08-2016, 09:56 AM #15
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(02-07-2016, 05:31 PM)turbojeep
(02-06-2016, 03:50 PM)DrewGerhan How did you make your alternator charge?

I just did the same in my TJ and I've got no tach or charging. I hooked the cam and crank sensor signal wires together thinking that would do it. Also, I hooked up the dark green wire to the alternator field wire as I was told to do so.

Hmmmmmm

I started with the original alternator pigtail, then spliced into the jeep's existing system. It was a while back and I don't remember off hand how I did it exactly.  I do know that I had to put in an excitor light. Does the TJ have one?

I still do not have a tach, saldy. It's in the works but haven't heard from the guy who was supposed to be getting it calibrated for me. 

On a different note, I should have some big updates on the jeep in the next two weeks!

There are two wires that it could be. A dark green and a dark green with orange tracer. I hooked the dark green to the blue coming off the alternator and it seems to charge just fine now. I think I'd like to add a diode inline, just to be on the same side of preventing battery drain.

I'm still at a loss for the tach. It worked when the 4.0L was in and from what I understand, TJs do not read engine speed from the ignition system. It comes from cam/crank sensor relationship. I wonder if I need to have a cam sensor plugged in as a mule, and then splice to signal wires of the two sensors together?
1981 300SD 230k miles "Gently Modified" Daily Driver

1999 F-250 7.3L Power Stroke 150k miles "The Usual Mods" Tow Rig

1981 300SD 190k miles "Heavily Modified" Big Grin  GONE
DrewGerhan
02-08-2016, 09:56 AM #15

(02-07-2016, 05:31 PM)turbojeep
(02-06-2016, 03:50 PM)DrewGerhan How did you make your alternator charge?

I just did the same in my TJ and I've got no tach or charging. I hooked the cam and crank sensor signal wires together thinking that would do it. Also, I hooked up the dark green wire to the alternator field wire as I was told to do so.

Hmmmmmm

I started with the original alternator pigtail, then spliced into the jeep's existing system. It was a while back and I don't remember off hand how I did it exactly.  I do know that I had to put in an excitor light. Does the TJ have one?

I still do not have a tach, saldy. It's in the works but haven't heard from the guy who was supposed to be getting it calibrated for me. 

On a different note, I should have some big updates on the jeep in the next two weeks!

There are two wires that it could be. A dark green and a dark green with orange tracer. I hooked the dark green to the blue coming off the alternator and it seems to charge just fine now. I think I'd like to add a diode inline, just to be on the same side of preventing battery drain.

I'm still at a loss for the tach. It worked when the 4.0L was in and from what I understand, TJs do not read engine speed from the ignition system. It comes from cam/crank sensor relationship. I wonder if I need to have a cam sensor plugged in as a mule, and then splice to signal wires of the two sensors together?

1981 300SD 230k miles "Gently Modified" Daily Driver

1999 F-250 7.3L Power Stroke 150k miles "The Usual Mods" Tow Rig

1981 300SD 190k miles "Heavily Modified" Big Grin  GONE

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