 | Home > My Defender > 110 automatic with Mercedes OM606 engine |
 
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| Dinnu Member Since: 24 Dec 2019 Location: Lija Posts: 3414   
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That is nice. Love the colour scheme.
 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black |
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9th Oct 2022 11:48am |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3677  
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Very nice indeed. Tell us more about the conversion!!
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9th Oct 2022 12:30pm |
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| LR90XS2011 Member Since: 05 Apr 2011 Location: bickenhill Posts: 3643 
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looks great DEFENDER 90 TDCI XS,
I hope everyone is well and your land rovers make you happy |
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9th Oct 2022 2:22pm |
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| 90 Dreamer Member Since: 13 Jul 2019 Location: Oop North Posts: 2161 
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Must climb vertical faces with that lump......
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9th Oct 2022 7:01pm |
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| Barneyboy Member Since: 19 Nov 2014 Location: Exmoor Posts: 1626  
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Very smart, and agree with Co1, please tell us more about it
cheers Paul |
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10th Oct 2022 5:12am |
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| MarkBrown Member Since: 03 Oct 2022 Location: Mid Wales Posts: 466  
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It's a 1983 110, rescued from a field, behind a barn.
I fitted a 98 mercedes om606 engine taken out of an e class. The conversion needs a mechanical injector pump fitting, which is taken from an older Mercedes engine. Larger pump elements are fitted to enable the engine to develope more power and run with no electronics. I've used a hybrid turbo feeding an aftermarket intercooler. DPUK supplied the air filter box and high mount alternator bracket, needed as the steering box is in the way. In it's current state of tune it's supposed to make up to 300 bio, but I've not yet had it on a dyno. I used an adaptor plate made by Gaz Fab which allows the engine to be fitted to a cable operated hybrid hp22 hp24 zf4 automatic gearbox, taken from a discovery 2 V8. Other parts I've used from that for the build are the front diff, front double carden propshaft, 1.2 ratio transfer box complete with handbrake assembly, which needs rotating and re drilling to fit, so the cable is long enough to attatch to the 110 hand brake lever. Ashcroft halfshafts are fitted to the original front axle, the original Salisbury rear has been converted to discs. Everything has been apart, checked and or replaced as needed, all the braking system is brand new, as is the suspension and steering. Inside I've used a ministry of defender dash behind a new bulkhead, two layers of mass loaded vynil with carpeting over. The seats are out of a mercedes slk and fit very well as they are thin, but also leather and sprung. All the components have been resprayed in tarpaulin grey and limestone. It drives very well with ample power on tap, quite and comfortable when driven, indeed it goes much better than the old discovery V8 used for parts. For me the combination of the engine and automatic gearbox totally transform the vehicle.  Click image to enlarge |
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11th Nov 2022 3:19pm |
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| rustandoil Member Since: 08 Sep 2012 Location: Cotswolds Posts: 743 
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The OM606 convertion has got to be one of the best engine choices for Defender.... Any detailed pictures of the build?
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11th Nov 2022 6:21pm |
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| MarkBrown Member Since: 03 Oct 2022 Location: Mid Wales Posts: 466
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No photos, I just kinda did it. Essentially I did this:
- Buy new 300 tdi chassis, for a 110. - Get a 1.2 lt230 transfer box from discovery 2 and some 300 tdi mounts. - Get donor zf4hp22 from discovery 2 and send to specialist to rebuild with stronger hp24 ( 4.6 p38 ) clutches. Make it cable operated, so fully hydraulic. Use 4.0l medium size torque converter. - Keep shifter from discovery 2 and make custom trunk ( or buy one from ashcroft's) inside. Extend shifter cable as it's too short by about 2 inches. - Get hold of Mercedes OM 606 engine, but a mechanical pump and fit it. Mine was from DPUK, indirectly. 7.7mm elements. - Sort out glow plug wiring, I used 2 circuits, with two 40 amp relays, so if one packs up, the engine will start, just, on the the three. - Buy a high mount alternator bracket, I used DPUK for this. - Get a OM648 rear sump, oil pump and dipstick tube off and fit, also block off the old dipstick hole. - I chose to fit a new hybrid turbo from DPUK, this is optional. - I also fitted a small water pump pully which is supposed to be better, some disagree, but I don't know. This then used 6PK2036 belt. - I fitted new glow plugs, valve seals, metal sump gasket and top end gasket set, along with metal vacuum pump gasket as the fibre one in the kit leaked. - I fitted the engine adaptor plate from Gaz Fab, then stood engine on its end to drop the gearbox onto the torque converter, or apparently holes need to be cut into the bell housing, to get at the bolts, which I didn't want. This needs to be done with carefull marking so that the oil pump in the gearbox doesn't break. - I fitted the transfer box, then used a forklift to shove in the engine and gearbox, bolted the transfer box and gearbox/engine together, then made my own mounts. I used a digital angle finder to make sure that the rear propshaft is at the correct angle, that is inline with the pinion, or it will vibrate. ( Mine doesn't, so I got that right! ) - I cut off the tdi engine mounts then made my own, making sure that the engine sat parralel to the chassis, not wonky. - I used a LHD 300 tdi throttle cable as it's long enough. - Reconnect heater. - Fit an oil cooler and get Pirtek to make up hydraulic hoses, also get them to alter the power steering hoses to fit. They will also make up the hoses for the gearbox oil cooler you have chosen. - I had a custom 3 inch exhaust made to fit by Longlife. - The air box is from DPUK. - Some sort of bracket needs to be made to connect the gearbox kickdown control cable to. - I fitted a pull to stop cable and fitted it to the old choke holder ( I think ) on the steering column. - I used a tdi fuel filter instead of the Merc one, as the plastic fittings on the Merc one were broken. - I fitted a 110 V8 radiator, but have on order an Allisport one as it gets warm up long hills. - The intercooler was the only one with bottom entry pipes, I used a universal kit to connect it up. - An EGR blanking adaptor is needed, this also gives the size of the intercooler pipes, 70mm I think. I welded a bolt in the manifold to block of the hole. - Fit the double carden propshaft from the discovery 2 as it's better and the correct length ( in a 300 tdi chassis ) Use new uj's if needed. - Get high low and difflock shifter for discovery 2, complete with cables and fit. - There are lots of other bits to figure out, but nothing daft. - That's essentially how I did it. - DPUK had loads of how to videos explaining things, like timing, fuel fittings, pump adjustment and so on. There's a public group called Mercrovers too. - If I was to do it again I'd start with a 200tdi chassis, as I believe that the transfer box sits further back, which would give more room at the front. This may or may not help someone! - |
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11th Nov 2022 8:09pm |
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| Mother superior Member Since: 05 Aug 2013 Location: Surrey Posts: 504
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Good Lord, She's lovely. I have a hankering for a D1 with that setup and this isn't helping! Oh woe, oh woe
My crusty old landrover, It will not go. |
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24th Nov 2022 4:12pm |
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| MarkBrown Member Since: 03 Oct 2022 Location: Mid Wales Posts: 466
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Thanks! It's worked out well.
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24th Nov 2022 5:20pm |
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| seriesonenut Member Since: 19 Nov 2014 Location: Essex Posts: 1211
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 2010 XS USW
1957 Series One 88 diesel 1958 Series One 88 4x2 |
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24th Nov 2022 6:21pm |
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| murph81 Member Since: 11 Sep 2022 Location: Ireland Posts: 63  
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Great conversion, must be lovely to drive!
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30th Nov 2022 10:31pm |
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| MarkBrown Member Since: 03 Oct 2022 Location: Mid Wales Posts: 466
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Just a little update for reference.
1. People say that the OM606 engines have no torque and are all top end power. This maybe true for some builds, especially those with huge turbochargers. I fitted a standard sized hybrid turbo to mine, whatever that is, and there is no lag at all, it's very drivable - far quicker off the mark than when in the old e300 which provides the engine. 2. They are said by some to run hot. I've had a few problems with mine, however I have now fitted a genuine 85 degree Mahle thermostat after finding the existing 78 degree part was sticking. I've also fitted an Allisport 110 V8 radiator, along with a pair of Spal electric fans. The temperature now stays consistent at 85 degrees, rising to 90 on a long hill. Whilst Green Laning the temperature will rise when there is no airflow, but the fans kick in at 95 degrees and cools it back down quickly. Click image to enlarge 3. There are many reports of the engine being jerky, making it impossible to drive just off tick over. I can't comment on this as mine is an automatic, so it's very smooth. 4. I've set up my fuel pump so that there is virtually no smoke, this is very simple to do, some builds that can be seen on YouTube are very obnoxious! 5. Air intake. I've got an off the shelf custom airbox but have had problems with the engine not being able to get sufficient air at 3/4 throttle, which leads to more black smoke than you'd think possible, followed by the engine suffocating. Obviously this is no good, so I now have fitted an additional 4inch intake, which has solved that problem. 6. Economy. Not much is written about mpg on this engine conversion, but my findings are generally I can get 20 mpg brim to brim on a tank, 25 mpg is achievable on a good journey, the best was 27 mpg on a motorway run at about 60mph, so in 4th gear lock up. Most of my journeys are local B roads in Wales, I also live down a track which means 10 minutes to the tarmac each journey, so not the best circumstances for economy. 7. Performance. I've not done any 0-60, nor have I had it on a Dyno. I would say that it would exceed the speed limit on a private road by around 40 mph, if anyone was brave or daft enough. Outside lane cruising on the motorway is easy peasy, as is joining via the slip road. Overtakeing can be carried out swiftly if necessary. It's very drivable and great fun on a dual carriageway. 8. Overall my opinion is that the conversion has far exceeded my expectations. It really is a joy to drive. I'll be starting another build in the future starting with a 90, the only difference is that I intend to use the 0M605 engine. This is currently less expensive to buy, has a very similar power output, will possibly be more frugal as there is one cylinder less and is shorter, which will give more room at the front ( with an automatic gearbox ). 9. It's simple. A starter to start it and a cable to stop it. That's it. Ideal for those like me who don't understand or see the benefits of a car full of electronic gizmos. It's kind of like a a TDI really, but about three times as powerful. |
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2nd Feb 2023 7:57pm |
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| hank Member Since: 12 Sep 2016 Location: South Wales Posts: 2301 
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Absolutely love this! > 110 XS Double Cab
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2nd Feb 2023 8:06pm |
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