Another FJ62 OM606 swap thread

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87freerunner said:
that is definetly a bonus, id be thrilled with 18-22MPG. It would be awesome to install a Long Range America 40 gallon tank as well and have about 800 miles of range. But im rubbing pennies together at this point with how much Ive spent on the swap so far. There are so many other things id like to do while the motor and trans are out but Im going to push that down the road for another day. Mainly, cleaning and undercoating the truck. It’s in great shape right now and Id like to see it stay that way for another 35 years! Id also love to re-spray the engine bay at some point. Maybe next year I’ll pull it all back out and do a light body restoration and respray. I do have a little experience from a previous truck build on body work and painting that turned out really nice. I restored this 87 4runner a few years back but have since solid axle swapped it and cut the fenders to fit 37's and turned it into a rock crawler. Theres too many "while im in here" ideas to entertain them all... lolView attachment 4091066View attachment 4091067
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I’m almost positive I’ve seen your 4Runner driving down Manchaca a time or two.
 
msods said:
I’m almost positive I’ve seen your 4Runner driving down Manchaca a time or two.
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Ohh yeah im sure. I drove it a lot more when it was Long Traveled IFS, not quite as much these days but its still fun to take around town here and there. I did just drive it about 650 miles round trip to Barnwell Mountain, wheeled it all weekend, and drove it home!
 
87freerunner said:
Ohh yeah im sure. I drove it a lot more when it was Long Traveled IFS, not quite as much these days but its still fun to take around town here and there. I did just drive it about 650 miles round trip to Barnwell Mountain, wheeled it all weekend, and drove it home!
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I tried to get my wife excited about 1st gen 4Runners after seeing yours haha
 
Oh I'm LOVING this. Looks like a more feasible conversion option than a 6BT.
 
Spook50 said:
Oh I'm LOVING this. Looks like a more feasible conversion option than a 6BT.
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for sure, I think the 6bt weight is close to 1100lbs. The OM606 weighs under 500lbs. I think the 606 and H55 combo is about 2-300 lbs lighter than the 3fe+a440. Definelty going to be interesting when its all done.
 
Made a little more progress today, started assembling the Tcase on the H55, I’m missing a gasket I thought I had so I’m stuck until I get the little gasket the sits at the upper part of the outer case where the shifter arm comes out. So I installed the exhaust manifold and ran the turbo oil line, and ran the injection pump lines to the injectors…
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87freerunner said:
That led me to engine swap ideas. LS was the easiest answer. Great motor, tons of power, lots of info and lots of people doing them in the cruiser world. So I bought an OM606 instead.

I picked up a 78k mile motor from a 1999 E300 turbo diesel. These motors can be run with a mechanical pump minimizing any computer control BS and love boost! The guy I bought the motor from was planning on putting it into a Jeep CJ and had already swapped to a rear sump oil pan, replaced the glow plugs, and had a pile of new parts to throw on it. It was a good place to start.

Current plan is a Borg Warner s200 turbo with a small 0.48 housing (S252) which should be good for about 350hp and 450 ft lbs of torque. 7.5mm dieselmeken pump, H55 transmission and split case.

It should be a nice upgrade from the 3fe, doubling the horsepower and torque, and doubling the MPG’s. Low end power is not exactly a strong point of the 606 but I cant imagine its any worse than the 3fe paired with the auto transmissionView attachment 4090988View attachment 4090989View attachment 4090990
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I have one of those Borg Warner s200 that I bought from Benzforce last summer. Only put 1k miles on it. I took it off this winter because I am just finishing up compounds on my 606.

One more thing. I put that Dpumpuk exhaust manifold on as well. I took it off this winter and found out that it was not flat.... the front couple cylinders are 1/8in off the head.... I would put a straight edge on yours before you put the motor in the rig. I thought mine was seated, and it was not. @DirtSniffer here is one for you.
 
fjdiesel said:
I have one of those Borg Warner s200 that I bought from Benzforce last summer. Only put 1k miles on it. I took it off this winter because I am just finishing up compounds on my 606.

One more thing. I put that Dpumpuk exhaust manifold on as well. I took it off this winter and found out that it was not flat.... the front couple cylinders are 1/8in off the head.... I would put a straight edge on yours before you put the motor in the rig. I thought mine was seated, and it was not. @DirtSniffer here is one for you.
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The mating surface wasn’t flat for the exhaust manifold? That’s frustrating! I’m sure Luke was a prick if you reached out to him about it. He’s impossible to go back and forth with.

What exhaust housing did you have on the s200? What didn’t you like about it? I appreciate any feedback, it won’t change my current plans but will help with any future changes.

I’m sure it won’t be the perfect setup but should be better than the 3fe and auto trans!
 
87freerunner said:
The mating surface wasn’t flat for the exhaust manifold? That’s frustrating! I’m sure Luke was a prick if you reached out to him about it. He’s impossible to go back and forth with.

What exhaust housing did you have on the s200? What didn’t you like about it? I appreciate any feedback, it won’t change my current plans but will help with any future changes.

I’m sure it won’t be the perfect setup but should be better than the 3fe and auto trans!
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Didn't even bother calling Luke. I plan on getting it machined and selling it. I went with one of the Benzforce manifolds before they sold out. It was a better fit for the compounds anyway.

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I felt the s200 didn't spool as fast as I wanted. But when I took everything apart and seen the exhaust leak, I am sure I was loosing a ton of boost. So in short, the s200 should be a great turbo for a single setup. Nothing is wrong with it. Its still like new. I have an external waste gate as well. PM me if you are interested in them. I have the smaller housing, its the s252.

I had also bought Lukes rebuilt injectors. And I didn't feel the 606 ran as smooth as it did in stock form. So I took them out this winter and sent them to a shop I have used many times in Duluth Mn. They said the pop pressures were all over the board. From 138 to 165 bar. He claimed they are all the same now.

I also went with a manual pump. Same reasons as you are. This winter I am changing to the Baldur DSL1 standalone controller and putting my EDC back on. I live at 1200 feet above sea level. And I like to drive my 40. Last August we were in Colorado at 13k feet. It did not like anything above about 8500 feet. Smoked, carried on like it was loading up. smoked, I need to say it again because it was so bad, It smoked!! LOl. Now, at 7000 feet in Colorado, it did just fine. In fact, we were racing and screwing around going up to Montrose one day at 85 mph and the only words to describe the drive is, it would run out like a raped ape!!

Hope that helps.
 
fjdiesel said:
Didn't even bother calling Luke. I plan on getting it machined and selling it. I went with one of the Benzforce manifolds before they sold out. It was a better fit for the compounds anyway.

View attachment 4093210

I felt the s200 didn't spool as fast as I wanted. But when I took everything apart and seen the exhaust leak, I am sure I was loosing a ton of boost. So in short, the s200 should be a great turbo for a single setup. Nothing is wrong with it. Its still like new. I have an external waste gate as well. PM me if you are interested in them. I have the smaller housing, its the s252.

I had also bought Lukes rebuilt injectors. And I didn't feel the 606 ran as smooth as it did in stock form. So I took them out this winter and sent them to a shop I have used many times in Duluth Mn. They said the pop pressures were all over the board. From 138 to 165 bar. He claimed they are all the same now.

I also went with a manual pump. Same reasons as you are. This winter I am changing to the Baldur DSL1 standalone controller and putting my EDC back on. I live at 1200 feet above sea level. And I like to drive my 40. Last August we were in Colorado at 13k feet. It did not like anything above about 8500 feet. Smoked, carried on like it was loading up. smoked, I need to say it again because it was so bad, It smoked!! LOl. Now, at 7000 feet in Colorado, it did just fine. In fact, we were racing and screwing around going up to Montrose one day at 85 mph and the only words to describe the drive is, it would run out like a raped ape!!

Hope that helps.
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Appreciate the feedback. I already have a new S252 and turbosmart wastegate. I’ll pull the manifold off and check it to confirm it’s flat. Thanks for the heads up!
 
Made some good progress over the last couple weeks. I added cruiser matts clutch pedal box onto my FJ62 pedal box and got everything hooked up, drilled the holes for the clutch master and bolted that up as well. I was also able to get the motor mounts burned in and the engine installed, transmission crossmember still needs some tweaking but its close. I also started buttoning up the little details like removing the restrictor in the fuel neck to fit a diesel pump at the gas station, and removed the fuel pump and just ran a line to the bottom of the tank for the fuel pickup.
Working on fuel lines and cooling system next...
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Ended up ordering an electric fan setup from Derale (part number 16831) its a prefect fit for the CSF radiator. Im going to have to move everything back a few inches to squeeze in the intercooler, and likely cut a lot of the core support to make it all work. Still waiting for the intercooler to arrive. Plan is to work on fuel lines and coolant lines until that arrives.
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I got the radiator/fan/intercooler setup mounted in the truck. Had to move the radiator back 2 inches and make a new mount for it. I cut the old mount from the front core support and welded it to some scrap tube that was laying around and fit that to the frame. I lined up the upper radiator mounting holes with longer bolts and tacked the lower mounts in place. I then made all my cuts in the core support for the intercooler and was able to get that mounted as well. Ill be squeezing a parralell flow condensor in front of all of that for the AC. Once the intercooler piping is all set I will be able to focus on fuel lines and wiring everything up. getting closer every day!
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