om 617 swap tons of pictures

BBCoffroad · 06-02-2012, 08:48 AM

well after toasting two 22re and always stalling them out i got the idea to put a diesel under the hood. i thought about a 4bt but to much power id have to swap in a 1 ton drive train with a little reserch the om617 was the anwser for me so here we go with the pictures.

got it from a local junk yard it was sitting in a pile of engines it was rough looking i really didnt think it was gunna run.

after cleaning it up a little i found that the upper oil pan was cracked.

i cut off the cracked section of the pan to fabricate a new lower pan.

i have a welding hobby shop on the base im stationed at i do all my work there.

these are just a few randon shots of me cleaning the engine up.

i didnt get a glow plug controller with the motor so i made my own its manual i used heavy guage wire a starter relay and i push button switch its simple and effective.

i made the fuel shut vavle out of one of my old toyota VCV off the 22re emmision system.

couldnt find AN adapters for my oil cooler so i modified the originals

i built the tranny adapter out of two pieces of .25 steel plated welded to each other a total thickness of .50 i located the engine mounting holes with the original merc adapter plate.

i made a pilot bearing adapter at work out of tool steel it came out nice

i aligned the tranny by inserting the input shaft into the pilot bearing and clamping the tranny to the plate and marking the holes its not the most precise way to do it but its proven so far to be just fine im working on a .75 thick aluminum plate currently that one will be blue printed to be precise.

this is my fly wheel sitting on the adapter i had it re surfaced and a new bolt pattern drilled by south bend clutch those guys a the best to work with great prices and fast turn around. the picture is before i had it machined.

got most of the engine clean and inspected it was time to test it to see if it worked or not it took a bit to get it to fire. the injection system was gunked up pretty bad.

the noise was the starter it was to close to the fly wheel and stayed engaged you can see it arking on the block.

BBCoffroad · 06-02-2012, 09:01 AM

got the engine bay all clean up for the swap i ended up only using 3 wires to controll the start up and shut down of the engine.

i got moving pretty quick once i got to the point of putting the engine in so theres not a hole lot of pictures to show progress.

got it there its a little tight had to put the rad in the rear didnt feel like finding a small one to fit in the front i could have moved the crossmember back and gained to inches but that would have been a lot of drive line mods and money so i mounted it in the rear.

BBCoffroad · 06-02-2012, 09:19 AM

i plated the frame from the front cross member to the cab with .25 plate on the inside and top motor mounts are 1.75 poly bushings there stiff as hell the hole vehicle shakes. i used 1.5 stainless pipe for the rad tubes goin to the rear i have plate style coolers for the oil and steering coolers i also used a steel vacuum can from summit. i made the exhuast out of 3'' mandrel bends it was my first time using mandrels it was fun fitting them all.

i have a boost/vac guage mounted on the roll cage pillar i also have a oil pres mounted just not mounted in the picture.

BBCoffroad · 06-02-2012, 09:37 AM

got all the kinks worked out and it was time to go wheelin to see if it would survive.this is a good before shot. the closest place to go wheelin is uwharie national forest its a good recreaction area 20 miles of trails, hiking its a fun place its near charlotte NC if your on the east coast its worth the trip.

a couple videos not the greatest though

at the end of the trip it did very well the only thing that broke was one of the tie rod ends and the vavle cover gasket started to leak really badly.

lrgrnr · 06-02-2012, 10:45 AM

Nice build!

I've seen you at URE before.....I remember hearing the diesel as you drove past.

Scuba · 06-02-2012, 12:19 PM

Looks really good! Nice build.

orange crusher · 06-02-2012, 01:39 PM

Very nice! Well done. Love diesel swaps.

RickerRicker19 · 06-02-2012, 03:12 PM

Looks good man!!

BBCoffroad · 06-02-2012, 03:52 PM

Quote:

Originally Posted by lrgrnr

Nice build!

I've seen you at URE before.....I remember hearing the diesel as you drove past.

what were you driving?

MandAtaco · 06-02-2012, 07:50 PM

That's amazing, great build!

lrgrnr · 06-02-2012, 08:21 PM

Quote:

Originally Posted by BBCoffroad

what were you driving?

Blue '06 Tacoma...

BBCoffroad · 06-03-2012, 07:13 AM

i dont think i saw u there

lrgrnr · 06-03-2012, 02:00 PM

Quote:

Originally Posted by BBCoffroad

i dont think i saw u there

I think it was during the Zuwharrie event.

no worries..........I'm sure I'll see you around.

me_tu05 · 06-04-2012, 11:28 AM

Nice job. They are stupid simple to wire up.

BBCoffroad · 06-07-2012, 09:09 AM

been thinkin about getting rid of it how much do you guys think i could get for it mods as fallows

5.5 SAS/rear leaf conversion
long travel front drive shaft
high steer conversion new P/S box not taped.
new T/C/clutch
yukon grizzly locker in rear diff 5.29 F/R gears
bilstien shocks 12''
xrc 8,000 lbs winch
custom bumpers
4xinnovations full roll cage
rear end cut off behind rear doors flat bed in its place
1982 OM617.952 5 cyl turbo diesel swaped with stock tranny and tcase adapted heat still works
120 amp alt/ dual batteries
cj bakini top covering rear cargo area
all guages work except rpm and oil pres auto meter oil pres installed and works

what do you guys think?

marco99trd · 06-07-2012, 01:15 PM

nice swap, what did the engine cost ya?

Wainiha · 06-07-2012, 02:24 PM

Quote:

Originally Posted by BBCoffroad

been thinkin about getting rid of it how much do you guys think i could get for it mods as fallows

5.5 SAS/rear leaf conversion
long travel front drive shaft
high steer conversion new P/S box not taped.
new T/C/clutch
yukon grizzly locker in rear diff 5.29 F/R gears
bilstien shocks 12''
xrc 8,000 lbs winch
custom bumpers
4xinnovations full roll cage
rear end cut off behind rear doors flat bed in its place
1982 OM617.952 5 cyl turbo diesel swaped with stock tranny and tcase adapted heat still works
120 amp alt/ dual batteries
cj bakini top covering rear cargo area
all guages work except rpm and oil pres auto meter oil pres installed and works

what do you guys think?

You just built it! It looks good to me. Why?

me_tu05 · 06-09-2012, 04:22 AM

Quote:

Originally Posted by Wainiha

You just built it! It looks good to me. Why?

Because the cool factor wears off when you wheel it and realize it is no better than a 22re.

Wainiha · 06-09-2012, 05:00 AM

Quote:

Originally Posted by me_tu05

Because the cool factor wears off when you wheel it and realize it is no better than a 22re.

That's gotta hurt

frorunner · 06-28-2012, 04:29 PM

how much do you want for it???

06-02-2012, 08:48 AM	#1
BBCoffroad Member Join Date: Aug 2009 Location: CAMP LEJEUNE NC Posts: 85	om 617 swap tons of pictures well after toasting two 22re and always stalling them out i got the idea to put a diesel under the hood. i thought about a 4bt but to much power id have to swap in a 1 ton drive train with a little reserch the om617 was the anwser for me so here we go with the pictures. got it from a local junk yard it was sitting in a pile of engines it was rough looking i really didnt think it was gunna run. after cleaning it up a little i found that the upper oil pan was cracked. i cut off the cracked section of the pan to fabricate a new lower pan. i have a welding hobby shop on the base im stationed at i do all my work there. these are just a few randon shots of me cleaning the engine up. i didnt get a glow plug controller with the motor so i made my own its manual i used heavy guage wire a starter relay and i push button switch its simple and effective. i made the fuel shut vavle out of one of my old toyota VCV off the 22re emmision system. couldnt find AN adapters for my oil cooler so i modified the originals i built the tranny adapter out of two pieces of .25 steel plated welded to each other a total thickness of .50 i located the engine mounting holes with the original merc adapter plate. i made a pilot bearing adapter at work out of tool steel it came out nice i aligned the tranny by inserting the input shaft into the pilot bearing and clamping the tranny to the plate and marking the holes its not the most precise way to do it but its proven so far to be just fine im working on a .75 thick aluminum plate currently that one will be blue printed to be precise. this is my fly wheel sitting on the adapter i had it re surfaced and a new bolt pattern drilled by south bend clutch those guys a the best to work with great prices and fast turn around. the picture is before i had it machined. got most of the engine clean and inspected it was time to test it to see if it worked or not it took a bit to get it to fire. the injection system was gunked up pretty bad. the noise was the starter it was to close to the fly wheel and stayed engaged you can see it arking on the block.

06-02-2012, 12:19 PM	#6
Scuba Veteran Member Join Date: Feb 2009 Location: CREEDMOOR SPORTS, Anniston, Alabama Posts: 7,731	Looks really good! Nice build. __________________ 99 Single Cab 2.7. Awaiting 3 Link SAS.

06-02-2012, 01:39 PM	#7
orange crusher #1 Member My Rig: 87 runner Join Date: Apr 2007 Location: Colorado area Posts: 2,740	Very nice! Well done. Love diesel swaps. __________________ 87 runner on 42s "bad luck"

06-02-2012, 03:12 PM	#8
RickerRicker19 Veteran Member My Rig: 1998 4runner 4x4 Join Date: Dec 2005 Location: Twentynine Palms, CA Posts: 814	Looks good man!! __________________ Semper Fidelis 1998 4cyl 5spd 4 Runner 1982 mini 4x4 Slowly learning one repair at a time

06-02-2012, 07:50 PM	#10
MandAtaco Veteran Member Join Date: Mar 2005 Location: Las Vegas, NV Posts: 1,674	That's amazing, great build! __________________ Just your average ttora backyard engineer. 01 Taco 96 Runner

06-02-2012, 09:01 AM	#2
BBCoffroad Member Join Date: Aug 2009 Location: CAMP LEJEUNE NC Posts: 85	got the engine bay all clean up for the swap i ended up only using 3 wires to controll the start up and shut down of the engine. i got moving pretty quick once i got to the point of putting the engine in so theres not a hole lot of pictures to show progress. got it there its a little tight had to put the rad in the rear didnt feel like finding a small one to fit in the front i could have moved the crossmember back and gained to inches but that would have been a lot of drive line mods and money so i mounted it in the rear.

06-02-2012, 09:19 AM	#3
BBCoffroad Member Join Date: Aug 2009 Location: CAMP LEJEUNE NC Posts: 85	i plated the frame from the front cross member to the cab with .25 plate on the inside and top motor mounts are 1.75 poly bushings there stiff as hell the hole vehicle shakes. i used 1.5 stainless pipe for the rad tubes goin to the rear i have plate style coolers for the oil and steering coolers i also used a steel vacuum can from summit. i made the exhuast out of 3'' mandrel bends it was my first time using mandrels it was fun fitting them all. i have a boost/vac guage mounted on the roll cage pillar i also have a oil pres mounted just not mounted in the picture.

06-02-2012, 09:37 AM	#4
BBCoffroad Member Join Date: Aug 2009 Location: CAMP LEJEUNE NC Posts: 85	got all the kinks worked out and it was time to go wheelin to see if it would survive.this is a good before shot. the closest place to go wheelin is uwharie national forest its a good recreaction area 20 miles of trails, hiking its a fun place its near charlotte NC if your on the east coast its worth the trip. a couple videos not the greatest though at the end of the trip it did very well the only thing that broke was one of the tie rod ends and the vavle cover gasket started to leak really badly.

06-02-2012, 10:45 AM	#5
lrgrnr Veteran Member Join Date: Apr 2010 Location: Asheboro NC Posts: 1,279	Nice build! I've seen you at URE before.....I remember hearing the diesel as you drove past.

06-03-2012, 07:13 AM	#12
BBCoffroad Member Join Date: Aug 2009 Location: CAMP LEJEUNE NC Posts: 85	i dont think i saw u there

06-04-2012, 11:28 AM	#14
me_tu05 Hawaii's Damage Control My Rig: 86 4rnr 1ton, 1UZ Join Date: Jul 2005 Location: hawaii Posts: 933	Nice job. They are stupid simple to wire up. __________________ 94 SC300 She boogies 86 4runner turbo diesel swap Now has a 1UZ

06-07-2012, 09:09 AM	#15
BBCoffroad Member Join Date: Aug 2009 Location: CAMP LEJEUNE NC Posts: 85	been thinkin about getting rid of it how much do you guys think i could get for it mods as fallows 5.5 SAS/rear leaf conversion long travel front drive shaft high steer conversion new P/S box not taped. new T/C/clutch yukon grizzly locker in rear diff 5.29 F/R gears bilstien shocks 12'' xrc 8,000 lbs winch custom bumpers 4xinnovations full roll cage rear end cut off behind rear doors flat bed in its place 1982 OM617.952 5 cyl turbo diesel swaped with stock tranny and tcase adapted heat still works 120 amp alt/ dual batteries cj bakini top covering rear cargo area all guages work except rpm and oil pres auto meter oil pres installed and works what do you guys think?

06-07-2012, 01:15 PM	#16
marco99trd Veteran Member Join Date: Nov 2007 Posts: 607	nice swap, what did the engine cost ya? __________________ 89 Reg Cab 22RE 88 $runner

06-28-2012, 04:29 PM	#20
frorunner Newbie Join Date: Jun 2012 Posts: 2	how much do you want for it???

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