jav1

I've gotten some requests so posting up some pics.

Project - 06 Lariat 4x4 5.4 3v (not a fan) to Mercedes 3.0l Turbo Diesel- (OM606.962) With upgraded VNT turbo, intercooler, electronic IP with DSL-1 ECU.\\


Old engine out.

jav1

mcr1911

Interesting build. I'll be following along. Is it just my eyes playing tricks on me or is the lift supporting the cab and front end by the running boards in the second picture?

jav1

No... you are correct. Lifted cab by running board brackets, Ill advised once I realized how heavy the cab was but the plan was to avoid / see deflection in case something was left "hooked up".

The Ford PCM stayed in place so I had to graft the critical sensors onto the Mercedes engine so the ECM would "think" the 5.4 was still installed.

This is the cam position trigger wheel (normally part of the phasers), and the cam position sensor (right side only) as well as the Ford Alternator, the engine adapter plate and Turbo removed (all new stainless studs on stock OM606 manifold.


Fabricated cam position trigger wheel to match the ford Phaser design- timed it to the crank position trigger.






bent up and attached direct to cam sprocket- spaced at proper distance to Ford Cam position sensor (on valve cover)




Ford Cam position sensor mounted to Mercedes valve cover -





Ford Alternator grafted in place - Ford PCM needs 2 Comm. signals- ribbed pulley same as Mercedes belt


Adapter Plate on, Stock KKK turbo removed- new EM gasket and stainless studs

jav1

Oil pan modified to clear diff, oil drain added clear of cross member, ford oil temp sensor added




Pan mounted to block




New 11" 2100 stall TQ w/ adapter and crank trigger wheel (stock ford CPS) to mate to Mercedes flex plate





Garret VNT turbo unprage w/ custom flange and stainless downpipes





Hewitt EGT probe



Custom Stainless turbo oil feed line

jav1

Engine test fit - full 3" stainless exhaust with new stainless diesel catalyst and flex joint (pre welding)





Intercooler and oil cooler plumbing lines



Cooling package saddles with oil cooler installed



New Extra Large Turbo intercooler plumbed in


Mercedes radiator plumbed in (stays with chassis now so no need to drain coolant to raise cab)




Flex joint and cat tagged in but used stock Mercedes "Clip" system to connect exhaust- clever design!

jav1

Cab dropped back into place over engine.




Decent fit - more clearance and serviceability than the 5.4



All hooked up- (still have some wire dressing to do. To be done after tuning... just in case there are changes.

tareed94

How are you planning to make the electronics work together?

jav1

It's been done for about 7 months.... trying to figure out how to post a video from my iPhone. Basically- the Ford PCM thinks the 5.4 is still in place. That PCM has stored codes because the non critical systems are gone BUT the PCM see;s all the critical sensors so everything works from the gauges all the way to the transmission shifting and I get no critical malfunctions. The engine works on it's own ECU and I was able to correlate the two so they don't fight each other.

I'll try to edit the pics and post the video as I get time but I wanted to upload most of the pics.

2dwoods

It sound crazy to some but it's all in the build its a lot of work but the satisfaction is worth it looks like should be nice