Engine swap

[Rattlenbang]

My L300 Delica engine is pooched, but I have a lead on a Pajero 2.5 with intercooler. Does anyone know if it's a plug and play swap or are modifications required. Seems like 4d56t engines are getting a little scarce out there.

[Growlerbearnz]

The block and head should be plug n play, assuming it has the same transmission as yours (auto/manual), manifolds and engine accessories may be different. Keep your old engine until after the swap...

That said, how pooched is pooched? The heads crack, sure, but the blocks are sturdy and easy to recondition, though possibly more expensive than just buying a second hand unit.

[motorang]

It may have a different oil pan as well. And keep the pulleys, as I think the pajero only has a single generator pulley while the starwagon has a double one.
You may not be able to mix head bits from both engines, as there were some differences in some years, like different valve recess, turbo watercooled or not, or hydraulic valve adjusters. But as long as you keep the Pajero head with the Pajero block it should be fine.

Andy

[Rattlenbang]

I've heard that the injection pump has to be swapped as well, which gives me pause: trying to time one in a Delica sounds like a real pita, on top of everything else. Would having an intercooler really change the fuel delivery that much? I've tried looking online to see if they have the same pump but couldn't find any info.

[Lapprentis]

A member here (Fleury) did replaced his Van's Engine with a brand new Hyundai D4BF bought from a Delica parts dealer from BC. He is very happy with the results. Would personally prefer too buying these brand new 5-6000$ instead of putting a 2-3000$ "NotSureWhatToExpect" used engine...Now if you have mecanical backgroung and already have an old engine that maybe different...

Lapprentis

[Rattlenbang]

I'd like to, but that's too much money for one of these old rigs. I picked up one with 160k from a Pajero - I just wonder if it'll run too rich since it wont have the intercooler on it, and whether I'll need to swap over the injection pump as well.

[motorang]

The intercooler helps to get more (colder) air in the engine so usually the pump is adjusted to put more Diesel in, and the power output is higher (same engine has 100 HP instead of 86 HP).

If you do not have an intercooler in your L300, I would just the old original L300 injection pump with that Pajero engine and that's it.

Andy

[Rattlenbang]

I was wondering about that, yet I'm reluctant to swap pumps, because that opens up a can of worms with timing issues. I have a dial gauge and so forth but it's real finicky, and access to the rear of the pump, which is required for timing, is very poor in the Delica. Not to mention that the new engine's pump has less than half the mileage on it. I thought there was a way of adjusting the richness of it?

[Growlerbearnz]

There is an adjustment screw on the back (the "full load" screw) which adjusts richness over the whole range, but it's unlikely you'll need to adjust that one. Where you'll be getting too much fuel/smoke is under boost, and that's adjusted by rotating the boost enrichment diaphragm (or "LDA" in German) so the pin is running on a shallower part of the cone.

There's a pretty good guide here: http://www.pug306.net/index.php?pageid=boschtuning but there are some minor differences on our injection pumps- mainly the lack of hot/cold idle adjustment, and lack of an LDA limit screw. All of which makes it much easier for us