1994 Toyota Turbo Diesel 4 Runner

D

DieselRunner

Adventurist
Its been a few years since I finished this truck but it was a fun project. Gen 2 4Runner with a Mercedes OM617 Turbo Diesel. The W56 5spd manual has always been a great choice for Toyota enthusiasts, so that needed to be a factor too. The goals for the project were a mechanical diesel motor and W56 swap. I also wanted to increase power, fuel mileage and the ability to run alternative fuels. Minimal electronics, no computers. I wanted the swap to look as "stock" as possible and be easy to maintain and work on.
Now typically, I work on 6x6 military diesels. I had just come off of an expedition rv project. I was interested in a cool down project that didn't require a forklift and crane. I had a need for a unique daily driver. Having owned a 90 V6 4runner previously, I knew it was a solid base to start with. My off road rv has a 12 valve Cummins 6bt with a 5 SPD Spicer military trans and t-case. So I wanted to keep the mechanical injection theme going and ability to use alternative fuels. After lots of research I settled on the OM617. The decision was based on availability of motor and parts, cost and reliability. I figured on a $5,000 budget and my labor.
 
I will be posting pictures, I have plenty. So the hunt began, I needed to source a gen 2 4runner, preferably with a manual trans. I needed a Mercedes W123 car and an 86-89 Toyota pick up or 4runner. I found a 94 4runner in SE Wisconsin for under $1500. The fenders were swiss cheese but it was clean otherwise. Manual trans w/178k miles. Ran and drove but needed a clutch soon. My friend had a running Mercedes w/under 200k miles. Luckily he needed tires and rims for his military truck so we could do some trading. Craigslist saved the day w/a 1989 4runner in NE Illinois. So I was ready to get started.
The 89 ran but was really not drive able. So I stripped it down for the aisin hubs, w56c trans and tcase. I also needed a lot of misc parts to be safe. I then welded new steel fenders in on the 94 4runner. I was driving the Mercedes and the 94 on a regular basis to make sure they were good before I did the motor swap. I still had to source an adapter plate for the W56 trans to the OM617. I still had to fabricate motor mounts as well.
 
1 of my friends had done the OM617 swap into a 79 Toyota pick up from AZ. I will post another thread on that later. He had bought a full TDswaps kit for around $1500 and some other parts. So he had an extra trans adapter plate and crank adapter. I had a friend with a water jet table and enough machining knowledge to make 5 plates. I also had access to a CNC shop for the crank adapters. So now it was time to start the swap.
 
Before I start digging up my build pics, I will give some background on the OM617. Its a 3 liter indirect injection straight 5cyl turbo diesel. Stock HP is about 125 and just under 200ftlbs of torque. The power curve is pretty flat. Its only around 60% efficient. The rpm range goes to 5500-5800rpm. It has shorter connecting rods compared to conventional diesels. Hence the higher rpm range. Stock boost is in the 7psi-10psi range. The motor weighs in around 600#s. Compared to the 325#s of the v6. There are better choices depending on your intended uses. Most of the other diesel choices are more expensive, less reliable and less mechanical. I think most of us would love to have a stock turbo diesel hilux. Having said all that and having put over 15k miles on the Mercedes. I am pleased w/my choice. 22-27 mpg in a 4300# vehicle that has 4.56 gears and 33" tires. Its quicker than when it had a v6. I can still upgrade the turbo and add an intercooler. The only real downside is limited upgrades on the injector pump. You can send it off to Finland for about 2500$. Max realistic hp is about 140-150 HP w/o spending enough money to justify a 4bt swap. At that point you really get into the off road only vehicle in my opinion. For my intended purposes as an off road capable inexpensive daily driver the Mercedes fits the bill. I need a good highway cruiser to haul my gear and get me to remote campsites. My rv is big, I needed a Scout vehicle for day to day life.
 
Whatever happened to the factory Toyota diesels from the mid-late 80's?

A Navy Warrant Officer I worked for back in the day had a diesel. Just Googled it to make sure I wasn't crazy (well, that's another story)...spotted this...apparently it was a Thailand model and VERY rare.

180px-Toyota_Hilux_ministry_of_energy.jpg
 
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Here is a little something to get started. I had to figure out the best method to put the pics up. Also had to sift through memory cards etc to find them.
Import only for the diesels. You can find jdm motors online for 2-3,000$ or find a basket case for sale and finish it. Somebody needs to flag that that 4 door pick up "porn". Your just going to make everyone want what they cant have. Next thing you know, their wives are leaving with the kids because dad is having another pickup imported. Those beautiful trucks are home wreckers. I will get more pics up this weekend. I really need to put pics up on my 79 pick up thread.
 
bob91yj said:
Whatever happened to the factory Toyota diesels from the mid-late 80's?

A Navy Warrant Officer I worked for back in the day had a diesel. Just Googled it to make sure I wasn't crazy (well, that's another story)...spotted this...apparently it was a Thailand model and VERY rare.

180px-Toyota_Hilux_ministry_of_energy.jpg
Click to expand...
Sailors are often bringing things from Thailand. Some are admitted, some not.
 
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