Sorry I can’t offer much advice apart from if you’re thinking of an engine conversion take a look at late 90’s E Class Merc’s. The cars themselves are complete junk, you can pick one up for £5-600. The engines are great though. The OM606 3 litre diesel produces 177bhp standard, 200 – 300 easily attainable if you want to throw some money at the project. Chuck the electronics away and fit a fully mechanical pump off a 603 early 90’s engine and you have a great setup.
I’m thinking of fitting the non turbo version, around 140bhp standard. Non turbo = way less under bonnet heat and a far simpler conversion in my G Wagen.
My 3 litre diesel G Wagen (603 engine 113bhp, in other words a slug), when used in Morocco had virtually identical consumption to a 300tdi 110, an auto TD5 D2 was maybe 10% better. I averaged 24mpg through UK, Spain and Morocco but that was with a light right foot and we always travel light. No roof rack and maybe 150kg of "stuff" at most.
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