Engine Bay Specifications (Future Diesel Swap), Engine swap Questions.

loremordred

loremordred

Observer
Hello Everyone,



If there is a thread with all this information available, I do appologize, I did not see a thread that cought my eye with concise clean format. I did not want to bury myself in old threads full of conversations to find the info.


Please consider this a fact base thread. I am looking to compile the data here, so we have our own source and easy reading reference.



I am currently in the process of looking for a better engine to suite my needs. I know the Gas V6 3.5L in the Montero works pretty fine. But I am looking into higher tow/torque specs, with less MPG loss.
I have been reading about new diesel engines with Turbo that are currently being produced and their efficiency is very well almost past that of our 3.5L specs.

HP can help, but I am more interested in getting easier time rolling this Heavy Truck ( Mazda3 as DD comparative weight), as well as towing capacity.




My needs/demands:
-Long distance travels
-Endurance/Reliability
-Economy MPG (20+ range)
-Tow capacity (water filtration system/reserve, 3 battery system, reserve tanks, gear, tow trailer, popup tent, camping gear) + ARB bar, 33's+, Winch
-Available parts for replacement - Traveling abroad (Mexico, Canada, South America) besides Continental US.


This will be my version of a highly mobile "home" and tool for work and play. Over-landing Very Often.


Feel free to answer what you know.


Questions:

1. If I put in a diesel engine, will I the Frame (engine bay) be able to take the weight difference? Would I have to enforce any parts of the frame/joints/axel?

i.e
3.5l = 500 lbs approx
4BT = 750+ lbs approx
(source http://www.cumminsdieselspecs.com/4bt.html)



2. Is there enough space to install a 6B series engine?

QSB 4.5L = 820 lbs approx
(http://www.cumminsdieselspecs.com/QSB45.html)



3. What are the available bolt in engines that can fit into the Engine Bay?

Note:Needs to have EPA sticker for California Law *
Note2: Any information about emissions for other non EPA vehicles would be appreciated.

Based of experience or hard facts (provide links/sources please).

i.e.
4M41 3.2L Di-D I4
4M40 2.8L TD I4


4. What Transmissions, axles, shafts, transfer case adaptions are needed? Any specialized parts required?


5. Do you know a more affordable Gas engines with Torq and Fuel Economy that I may have not considered? Free suggestions.



6. Do you have any other Cost Effective upgrades besides gearing and engine tune? Hybrid/Alternate fuel/New engine or motor?




California Law for Diesel: The engine must be readily available for that Model and Year, or Newer Year, model and manufacturer than the current Vehicle. Must have EPA sticker for approval (USA wide requirement?).
 
J

JamesW

Adventurer
I have the 4M40 in mine. I think it's a fantastic engine,pulls well from 1500 rpm to above 3500. I've modded the on boost fuel pressure and turned up the boost (these are both free mods,just takes a few hours) . Those combined with a free flowing air filter and a stainless exhaust means that the truck has loads of power should you ever need it.

It should fit into a 3.5,the 3.5 petrol and the 2.8 diesel both have body lifts from factory to account for the bigger bell housing compared to the 3.0 and the 2.5.

Compared to the 2.8 the 2.5 is pretty weak,and I don't think they make a great long distance cruiser because of the gearing. they are doing 3500RPM at 100Km/h which is way too high for a diesel.

I'm not sure on what laws you need in the US for engines,but some CAT excavators have the 4m40 engine in them,so it might be acceptable to use the mitsubishi 4m40 seeing as the engine is already in use.

Things to look out for with the 4m40 is the head gaskets and the head. They are pretty prone to head failure if the cooling system is not looked after. Go over to POCUK.com and ask some questions there,they will be able to tell you if the engine mounts need to be modified much
 
O

off-roader

Expedition Leader
From what I've seen/read, the 4m40 and newer diesels where never sold in N.America although some/many have been imported into Canada.
 
Toasty

Toasty

Looking for that thing i just had in my hand...
4M40 slaps right in and only requires 1 wire to operate. Do it, there's a good write up on the internet detailing the swap but it's one of those that will just work. Buy the motor and trans combo from a Pajero, your trans crossmember needs to be turned around. Get on it, and post pics!
 
loremordred

loremordred

Observer
Thanks for the Links and the Info.

I do not know the laws in Texas (according to 4x4wire profile), but I believe the engine needs a EPA cert. Did it have it by any chance? Or is there a law or roundabout that I don't know of?

I have recently been reading up about Diesel Turbo kits and also LPG injection on diesels. So getting any, will increase the power output with the right mods and adaptions to it. Souce (http://www.autospeed.com/cms/A_112610/article.html)

I am still looking for the biggest diesel I can put in the truck to enhance its weight capabilities with gear and extras. A new question is, will a Dodge Ram 1500 Cummins 5.9 fit in the engine bay of the Montero. I still need to get engine Dimensions from the 3.5L and the available space in the engine bay.





Thanks for the tips guys.

I will be updating this thread as I get more information and find motors available.
 
ca18_sean

ca18_sean

Adventurer
I'm no expert on California laws... but it's my understanding that 4BT engines aren't legal for use in a passenger vehicle in certain states, California being one of them, because they were only EPA/CARB certified for industrial/commercial equipment.

Something like a 5.9 Cummins from a Dodge 1500 truck might work, but another rule I've read is that the engine must be sourced from a newer vehicle than the vehicle it's going into (for example, a 1999 engine swapped into a 1995 truck is OK, but not vice versa).

California has too many rules to keep up with... lol.
 
O

off-roader

Expedition Leader
ca18_sean said:
California has too many rules to keep up with... lol.
Click to expand...

No doubt.

The spirit of the law is that they don't want you to put in an engine that produces more pollution & or is less efficient than a newer engine, so that's why they don't allow older engines in newer vehicles and the engines.
 
O

off-roader

Expedition Leader
Well if its not a stock engine, it will have to be inspected at a state inspection station rather than a simple smog station. Plus those shops that will "smog" it for a fee are becoming more & more rare. There's a lot of enforcement going down over the past few years. CARB agents trolling forums just like this one looking for leads on where to find a shop willing to do that. Of course if you have a personal friend you know who operates a shop who's willing to loose their license and pay the added fines then all bets are off...
 
Last edited:
SoCalMonty

SoCalMonty

Explorer
off-roader said:
Well if its not a stock engine, it will have to be inspected at a state inspection station rather than a simple smog station. Plus those shops that will smog it for a fee are becoming more & more rare. There's a lot of enforcement going down over the past few years. CARB agents trolling forums just like this one looking for leads on where to find a shop willing to do that. Of course if you have a personal friend you know who operates a shop who's willing to loose their license and pay the added fines then all bets are off...
Click to expand...

I did until about 6 mos ago. He went out of business, but I don't think it was due to a CARB fine. He had other issues and was behind on rent. I have a lead on another one that a good friend of mine uses. He's about 35 miles away, and a little more expensive, but it's still not a bad deal @ $200. I need it for the Volvo's tags in August. :(
 
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