What this conversion will get you is a completely reliable, strong and long-lived engine that will take you to the middle of nowhere with the confidence that you will return. It is relatively good on fuel and will extend your range and require less fuel to be brought along on expeditions. It will give you good manners off-road and enough torque to get through technical sections without a lot of throttle.

This engine conversion is not for the faint-of-heart. It is not for a shade-tree mechanic. It is very involved and at times difficult and frustrating. It requires skills in machine work, aluminum and steel welding and electrical and plumbing work, and a fair amount of problem solving and mechanical abilities. It will also not be cheap. This adapter gets the engine and transmission together but there will be other things that need to be built/changed/purchased to complete the conversion. Most of all in requires enthusiasm and a commitment. If you go into this half-hearted you will never finish it. It will take large and equal portions of cash, time, patience, and perseverance.

The engines:

The 616 engine is a 2.4L diesel out of a 240D

The 617 engine is a 3.0L diesel out of a 300D

The 617 came as either a turbo or non-turbo version

The 616 is between 68 and 80 horsepower depending on year and who you talk to

The 617 non-turbo is around 95 horsepower

The 617 turbo is around 125 horsepower

All are high-revving engines that develop their peak horsepower over 4000rpm.

Operating rpms are similar to a gasoline engine so no change to the gearing is needed

The 616 engine works best in an 88" truck but is probably too underpowered for a 109 to be worth the trouble. The 617 turbo would be best in a 109 but unless you are starting with a 6-cyl version truck there will need to be modifications to the bulkhead and/or radiator support. I get this question more than any other. Yes, you will need to cut and modify your bulkhead to fit the 617 engine unless you have a 6-cyl bulkhead. With a 616 engine, no modification to the bulkhead is necessary.

Some, but not all of the things you’ll need to modify or fabricate follows.

Fabricate motor mounts

Relieve outer edge of flywheel to clear bellhousing

If using a 617, find a 616 manual flywheel and balance it to the 617 engine

Clearance clutch input splines

Cut and weld the upper and lower oil pan

Engineer remote oil filter and cooler system

Redesign throttle linkage/cable

Re-plumb heater hose outlets

Modify fuel feed line and install fuel return line to fuel tank

Install a vacuum shut-off line and switch to the dash

Locate and install a 615 exhaust manifold (616 engines)

Design and build the exhaust system

Design the glow-plug power system

Change/fabricate the engine wiring harness

Trim or remove mechanical fan and/or install electric cooling fan

Modify bellhousing to clear starter or buy a Mean Green starter

Find radiator hoses that work

Find, fit and wire a stronger alternator

The cost of the kit is $700 plus shipping.

If you are still reading and still interested, email me here