86 Turbo 4runner getting a OM617

[89lc]

I thought maybe I should post this engine swap here since there seems to be more info on the subject in this forum.
I acquired this 86 turbo 4runner from my friend, he wanted the turbo stuff for his own build and I had always wanted a diesel in my 4xtoy. I had originally wanted to put a cummins in my FJ62 and life got in the way. I couldn't afford to put one in my landcruiser and after wheeling it I realized that it was too heavy to go where I wanted to go. So after a little thought, I sold it to fund my 4runner.
My plans for the 4runner are:
-OM617 mated to a toyota 5spd trans with dual transfer cases with a triple stick shifter assembly.
-Straight axle conversion with a raised front spring hanger to reduce the amount of lift and rear springs up front. I will be using a 86 chevy D60.
- 4 link rear suspension to match the front suspension lift (hopefully no lift), using a 14 bolt rear axle from the same truck the front came from.
- F-150 fuel tank
- internal cage and bumpers, sliders and interconnecting fender bars.
- some paint and lots of little things that I have to figure out.
A friend of a friend has a german car shop and sold me a OM617.950 missing parts for $500 and he has a donor vehicle that I could take the missing parts from. I picked up the incomplete engine and started to work on my adapter plate and pilot bearing spacer. I dropped off the flywheels to get the toy matched to the mercedes and new mounting holes drilled. The place that I took them to decided to just zero balance the flywheel because they figured I was crazy and didn't know what I was talking about. Turns out the mercedes flywheel was only 5 grams out of balance, so I decided to just use the toy flywheel as is.

[89lc]

While I was waiting for the flywheel, I started to build my dual cases. I ordered a output shaft from Bobby Long and a Marlin Crawler adapter with a 23 spline input. While taking the other transfer case that I had bought, I found some broken gears and worn out bearings and what appeared to be very muddy oil. My crawler box was now on hold because I had to order more parts for it that the dealership doesn't carry.
I got the parts I needed for the dual cases and worked on the triple shifters while I waited for them to come in. Right now I just have to make the linkages for the shifters and paint them. The dual cases need the shift rails trimmed to fit correctly in the adapter.
The adapter plate for the engine to trans was kind of frustrating. I used the information from Someone's swap to make my adapter. I tried to find a piece of 5/16's steel or aluminum but was told it would cost around $200 for a 2ft. square. I said screw that, my friend had some 3/16's left over from a project, so I cut a piece of that and after getting the holes drilled into the 3/16's I welded the scatter shield from the auto trans that I pulled from my 4runner to it. It didn't quite make up the 1/8 inch I needed but was close. When I had the trans bolted to the engine, the pilot bearing and input shaft looked to be sitting very nicely together.
I received a call today from the guy I got the engine from saying that I can have the entire engine from the donor car and anything else that I need from that car. The other engine has around 120K on it and was missing the turbo. I also believe that the engine is a 617.952, which is great for me because I like more power. The only problem I have is I don't know where the shut off solenoid or overboost solenoids are and would like to get them when I pick up the other engine.
Thats all for now, hopefully I will be getting a engine hoist soon so I can get that motor in there.

[89lc]

I finally got a little time to work on the 4runner. I had set the engine in the bay and figured out that I needed to get rid of the front suspension to mount the engine the way I wanted to. So I borrowed a plasma cutter and went crazy.

Now I just have to do a lot of grinding and weld on some frame plates and get my motor mounts together, then maybe I will have an engine sitting in there for good.
Oh and I got another engine from the same guy I got the first one from for free, he didn't want to take all the parts I needed so he just gave me the entire thing. It has 120K miles on it and a couple of the guys that work at that shop told me that the engine runs cherry.

[robscj]

looks like you got a good start keep it up and us posted

[89lc]

Thanks, as soon as I get my 10 posts I'll post more pics up.

[89lc]

#10!!!!

[89lc]

Here are some pics that I have taken so far.
The holy block

Pilot bearing spacer, I had to make a new one when I got the new engine because I cut the old one out to use the bearing again.

Transfercase gear carnage. I love used parts.

Flywheel on first motor

Trans lined up but not bolted on.

Dual case adapter that was sent to me. This was a return that somehow got put back on the shelf and then sent to me. See the gap at the top.

[89lc]

Dual cases mocked up so I could make a remote shift assembly for the rear transfer case.

This is what the little box looks like on the inside.

This is the welds on the frame from the factory I think. What happened to quality control?

Oh No!!! my front suspension dissapeared

Oh, there it is, on the floor.

So many brackets to cut off.

Thats where I am right now. I will be moving at a snails pace since school started up again. I will be grinding the frame brackets off and welding on 1/4 inch plates to reinforce the frame. I will also be taking the parts the new engine needs off the old and putting them on the new. I still have to mount my F-150 fuel tank and run the lines for it. And the list goes on and on.

[89lc]

Since I have such limited space in the engine bay, would you guys recomend running a meth inj system instead of an IC or should I try to fit an IC somewhere?

[DieselHilux]

You dont need an IC or meth injection, these engines run for 500K plus miles without one so I dont see why you would worry about it.

[cRiPpLe_rOoStEr]

cool truck...

[89lc]

You dont need an IC or meth injection, these engines run for 500K plus miles without one so I dont see why you would worry about it.

My friend thinks an IC or meth would be a good idea because it is going to be used mostly for wheeling and there are some really big hills you have to go up to get to the trails. Plus I am going to add a larger turbo and do some tinkering with the IP after I finish the rest of the 4runner. So, I guess I'm just trying to think ahead and if need be make room now if I need one or the other.

[89lc]

cool truck...

Thanks

[cRiPpLe_rOoStEr]

My friend thinks an IC or meth would be a good idea

i would prefer an ic instead of methanol injection...

[89lc]

So after working on the 4runner today, it looks like I might not be able to keep the ac. :'( I did get the engine in and mounted. Here are some crappy pics.


No room up front, guess I have to cut up some stuff to fit the radiator.


Oil pan sits kinda low but I should be able to work around that.

Thats about it for this weekend.

[DieselHilux]

What kind of radiator you plan on running???

[89lc]

I'm going to use the factory three core radiator for now.

[Jim_Morrison]

bump nay updates

[89lc]

I got the dual cases installed and cleaned the garage a little, thats about it.

[toyota_17]

So the stock 1/8" toyota plate welded to the 3/16" steel plate worked nicely? It would make the same thickness as the 5/16" adapter, so im assuming it went together nicely?

Why does your motor look so much closer to the rad the someones setup? Maybe because of the body lift?

p.s. nice work so far man, looks great!

[89lc]

Thanks, the adapter is not quite 5/16's, is about a 32nd off. I still dont know how it will work because the clutch plumbing is not in yet. I think the radiator is a different size than someone's, I have the factory 3 core from an auto trans and I think his is a two core. I'm sure the body lift helped with fitting everything.

[89lc]

I picked up this turbo from my friend the other day. Its a 61mm or 62mm off of a single turbo setup on a Mk IV Supra. He told me that it spools really fast on the 2jzgte's and is good for around 500 hp. That should be fun to play with.




My friend also gave me a remote oil filter from a chevy blazer. I was thinking of using this in place of the oil filter but maybe I should just make a block off plate and mount for the merc one.

[OM617]

That big turbo is going to make the 617 a dog to drive.

"Spools really fast" to a Supra owner is anything that builds boost under 4000rpm.

[89lc]

That big turbo is going to make the 617 a dog to drive.

"Spools really fast" to a Supra owner is anything that builds boost under 4000rpm.

True, most Supra guys are like that. My friend builds them and is basing this off of when he test drove the car it was on before swapping the turbo out for a larger one. He thinks it spools up just as fast as the stock twins and that it should work really well on the 617 because they are both 3.0L's. It was free so if it doesn't work then I can always sell it.

Edit: He told me I would get full boost by 3000 -3200 rpms. That could be close to 2 bar, more than I think I could use.

[OM617]

Gas turbos don't work the same on diesels. Gas exhaust is much hotter and higher velocity while diesel is relatively cool and slow.

[dealwithit]

plus the 3.0L supra engine with dohc, 24v, and a 7500 rpm redline flows probably 2-3 times the air that an old 617 will. i would really only try a turbo that big if you had a serous fuel system to use the airflow abilities, and get it spooled up better. that combined with the factory turbo would make for a great set of twins tho

[89lc]

Hmm, maybe I'll just give it back to him if he wants it. I didn't know the difference between the exhaust on diesels and gas, good to know. I think I would pass on a compound setup, this thing is for wheeling so simple is better to me.
Thanks for the info guys.

Dealwithit, I take it you like mazdas

[dealwithit]

hahaha yah, you could say that lol.

[89lc]

Small update, I re-did my motor mounts because the stock ones were gona rip in half. I used 1.5" rubber spring bushings to mount it. Came out pretty good, now I don't have to worry about breaking motor mounts.

[89lc]

Picked up my volvo radiator today, $107 not too bad, just hope it works. I guess dieselcruiserhead will find out before me though, so at least I can return it if it doesn't work for him.