sprinter 2.9 td 602 engine swap.. into 300gd ....

Jerry I could possibly contribute an answer if you could provide chassis number of the sprinter and. or engine number and gearbox number of the donor vehicle in order to see why you are only at 55 MPH and at what rpm is that at?

Rakesh

I am looking at the details currently but just wanted to ask, are you sure you are NOT in low ratio at the transfer box?

What wheel size are you currently on?

I will come back after digesting your given data.

Rakesh

Hi

Some data i have from a previous enquiry with the same issue, i think REVS are crucial here....not the top speed.

""There were a few peculiarities with the 312D Sprinter Turbo, i am assuming that since you are running the ECU that you have tried to replicate the Sprinter set up as much as possible when it was first installed to get it to run correctly. Did you have it converted, sounds like you maybe did not do the work, but were you involved?

It sounds as if you have "limp home" mode that is limiting the engine revs.

Have you had any work done to the engine whilst swopping over?

Was any other work carried out at or around the same time, even if it does not seem related?

Any idea how the ECU is linked to the G's ABS system?

Sorry for all the questions...!!!! All part numbers quoted are for the Sprinter type parts, obviously you may have a combination of Sprinter and G parts?

In the Sprinter this "limp home" could have many causes and a few were really simple...

1) Is the engine running normally at idle and pulling through the gears normally on first start up? Does the Turbo sound like it is spooling?

2) Not sure this applies to your G but the Sprinter ran a dual stop/tail bulb, it could be forced into its holder the wrong way, even though it had offset pins, the effect of this was the ECU thought the Brake Pedal was depressed and cut the revs, it basically would not let you accelerate and brake at the same time. This information may still be relevant....

3) The Sprinter also had a Switch on the Brake Pedal that feeds this information to the ECU, these switches which you may have had to replicate to get it running on the install are mounted in a position on the back of the Brake Pedal that is in an area that gets lots of dust, dirt and moisture and the switchs tend to get full of this and either stop working or stick, they also have a tendency to collapse inside with similar effects. Only cheap to swop. A000 545 69 09 and also Handbrake Switch A001 545 06 09

4) Similar "limp home" issues could be generated from a faulty Clutch Pedal Sensor Switch A004 545 18 14

5) Are you running the EDC warning system with a light on the dash? I pressume not as this should throw a fault light for EDC.

6) Faulty Dual Mass Flywheels can have a limiting effect on engine revs A602 030 23 05 also it's the teeth on this that the Crankshaft Sensor reads off, have they been damaged or bent as it can limit engine revs

7) Collapsed Vacuum Pump on the engine can cause fuelling issues A000 230 43 65 by throwing the Timing out.

8) Injector with the wire or Needle Motion Sensor A000 010 16 51?

9) Vacuum pipe system leakage on Engine, Turbo, Inlet Manifold, Intercooler Piping or EGR systems

10) Collapsed or blocked EGR valve A002 140 26 60 if still fitted can limit revs

11) Faulty Temp Sensor A004 153 10 28 and Shut Off Solenoid A000 074 48 88 on the Injection Pump

12) Faulty EDC Temp Sender on the Cylinder Head A005 153 63 28

13) Faulty Water Temp Sender A005 542 10 17 on the Cylinder Head

14) Faulty Crank Position Sensor A003 153 72 28 on the rear of the engine or dirty Sensor or misaligned Sensor

15) Faulty Radiator Coolant Level Sensor A129 545 02 24 on the Radiator

16) Are the Coolant, Brake and Clutch fluid levels correct?

17) Split or incorrectly installed Intercooler Pipes to Intercooler and Turbo

18) Faulty Intake Air Temp Sender A006 153 20 28 on Intercooler piping

19) Faulty Intake Air Pressure Sensor A011 542 07 17 on Intercooler piping

20) Faulty Speedo Sensor on the rear of the Gearbox A005 542 58 17

21) Faulty RPM Sensor A010 542 22 17 on lower rear of engine or misaligned or damaged

22) Engine wiring loom used to rub through on the N/S Engine Mounting area feeding up to the ECU

23) Faulty or seized Turbo Wastegate A602 096 00 69

24) Faulty EGR changeover valve A001 540 86 97 if still fitted

25) Faulty Accelerator Position Sensor A011 542 86 17 on the Accelerator Pedal

26) Broken Accelerator Pedal / Cable Clip A901 988 01 78 or sticking Cable A901 300 09 30

27) Faulty Ignition Switch on the Steering Column A000 545 81 08

28) Wiring and Connectors to all of the above

29) Blockage in the Fuel lines or collapsed or blocked Fuel Sender in the tank A901 542 13 17

30) Cracked or split Fuel Filter Housing A604 092 01 08 or leaking Fuel pipes or O ring seals or Leak Off (Spill) pipe split

Will that give you some more things to check whilst i have a think about it?!?

These are not in any particular order of priority except the first couple or so""

Hope there may be something in there.....whilst Rakesh gets his thinking cap on :)

Looking at the 312D specifications there is nothing to suggest a gearing issue. I would go along with Gav's suggestions of an ECU matting issue. Or, at least your attempts to mimic 312D characteristics grafted onto the W460.

You may try to be rid of the ECU by changing over to a mechanical injector pump.

602 sprinter is different engine from resr of 6xx family

Ecu rotary pump Dirct injection will not accept pes inline mpump....from memory vp59 ecu rotary can be replaced by vw lt rotary or vovo ditto from the 90's

Quite a few commeNts on other forums

Also have a neighbour who has run one with cut down wiring loom from donor sprinter for 8 years no probs

​Aah the first all day at 100 mph mway van , all gone now

Hard to type from my phone as keyboard covers text input