I am planning to rebuild a 616 from a 240d to put in a small pickup. The 617 will not fit, at least not without major work. I have a 617 in rough shape missing parts, but the turbo, and manifolds are there. I have seen in other posts that the manifold can be modified to fit the 4 cylinder. It seems to me that the turbo should work as well, but might be a little slow to spool, being that it is for a larger engine. This would be ok for me as the pickup will be mostly highway driven. Trying to keep costs down, but of course need it to work. So am I barking up the wrong tree? and should be looking for a different turbo? or is this turbo going to work? Have a full machine shop and reasonable welding skills, so fabrication is no problem.

You will get differing opinions. Rayjay made a turbo kit for the 616. I had a small IHI turbo from a Ford Probe & it spooled nicely. If you're going to alter the 617 manifold, why not get a junkyard turbo from a 20 - 2.4L engine & modify the manifold to your likes. Less lag & keep it down to 5-6 Psi.

(09-06-2010 04:49 AM)yankneck696 Wrote:  You will get differing opinions. Rayjay made a turbo kit for the 616. I had a small IHI turbo from a Ford Probe & it spooled nicely. If you're going to alter the 617 manifold, why not get a junkyard turbo from a 20 - 2.4L engine & modify the manifold to your likes. Less lag & keep it down to 5-6 Psi.

I modified the factory exhaust manifold on my om601(newer version of your 616) to hold the turbo from a Mitsubishi mighty max which is a 2.3 factory turbo diesel, I had to build a intake plenum from scratch that takes air fromthe turbo through a top mount intercooler, hope that helps! I just got real luck at the junkyard to find such an appropriately sized turbo!

What kind of pick up are you using? There is a post of a om617 (i believe) in a s10 blazer.And i planned on doing the same in an s10 or ranger.

Here's my turbo/top mount IC setup...

And no pickup for me... Just this

What are you using for a transmission in that thing I may have to come check it out I'm in the Longmont / Platteville area!

(09-08-2010 12:16 AM)willbhere4u Wrote:  What are you using for a transmission in that thing I may have to come check it out I'm in the Longmont / Platteville area!

The factory 84 190d trans whatever that is, Suzuki samurais use a divorced gear driven transfer case from the factory, so a small custom intermediate shaft was all it took to complete the drive train! Feel free to come visit anytime, this project is far from finished but is coming along nicely!

Mine was in a Sammy with 6 wheel drive.

Toyota pickup, 2 wheel drive. the other option would be to convert the 240d into a pickup. Still would want to add the turbo. I just picked up a 240d for parts and the front half is cherry. Hate to part it out.