Replacing OM 617 by OM 602 turbodiesel Electronic Control

i will use this post to restate some of my own hard learned lessons;-

'iron head' 617 and 616 engines and associated gearboxes have the starter on the opposite side to ALL subsequent MB diesels so all swaps must include a gearbox and flywheel clutch assy.

602 'sprinter ecu rotary pump is DIRECT injection.There are several good conversions on the forums ,BUT a lot of painstaking work removing and using the relevent parts of the sprinter loom related to the ecu, starting at the key sensor.

There is also an issue with the inlet manifold which goes back over the cam cover and has to be changed/fabricated [I have seen a 'power bulge' G bonnet-yuk]

You have to have the egr system [also yuk] retained OR be very clever to fool the ecu and you will never have more than c.125 bhp and the harshness of direct injection.

Check the forums for 662 musso conversions with classic M pump injection ,no electronics needed.

I am working on a 200bhp 662 using 6mm elements and E300 kkk turbo and hope to be able to soon report on test run/dyno tune results

My daily driver is a 461 with  standard 662 power ,good intercooler and 5.5 mm pump properly set - those who have seen it know it goes well

OK so the engine is in .....you have 2 routes 

1] strip out the wires from a sprinter starting at the key switch and fit ecu to engine - this has been done by some people but needs specialist knowledge.

2] there are postings on the web from eastern europe that describe the use of a 5 cyl rotary pump from 5 cyl VW of the 90's and also volvo rotary pump

In answer to your question an 'M' pump wont fit at all ...wrong pump drive sprocket - you could try with the sprocket from the inline pump HOWEVER injection pressure from rotary is much higher than inline m pump and you CANNOT change injectors as they are quite different type and fitting ,there is then also an issue with injector pipes which have to be made especially.

EGR is exhaust gas valve which should be deleted.

My feeling is find a 5 cyl rotary pump with mechcanical actuator would be best solution

  Yes Gav you are right. The engine i used was out of a 2000 312d. JOHN

No, not at all..

Just that although the OM602.98X engines are all the same mechanically they all run in different states of tune and how the power is delivered depending if it was in a Small 4x4 a Medium or Large Van etc.

All the ECU's will be different

Gav

Very interesting. I have a small collection of ecu from 312d vans and wondered why the part numbers differed. My engine came from a  large van. Am glad it did as the power is excellent and not much different from my g270cdi which has been chipped.