3.0 v6 4M40 swap compatibility

[roaming knome]

Hello all,

I am planning to swap a 4M40 TD into my ge1 Montero/Pajero. The donor vehicle is a JDM 1996 Delica Spacegear 4wd. My main concern is a 4M40 engine/trans/wire harness from a Delica the same as one from a Pajero? I keep hearing different things, some say it will work and others say that they are different and have different components, mounts, different smog devices, and am now completely confused. Of course the person selling me the complete engine/trans/wire harness setup is telling me it will fit/work no problem. I was then pointed in this direction and here I am searching for a little clarification before I drop the $$$ for something that might need a lot more work to swap over.
If there is little to no differences should I get the 1996 JDM Delica engine/trans?
Or should I look for one that is from a Pajero?
Any and all held/advice is greatly appreciated!

Thank you,
Adrian.

[-Scott-]

The 4M40 td generates significantly more torque than the 3.0V6 in the Gen 1, so it uses physically larger gearbox, transfer and rear diff (and probably front diff, too). In the Gen 2 Pajero, Mitsubishi moved the body mounting tabs higher on the chassis to create clearance for the larger components. In the NJ, the "factory body lift" was 30mm.

I don't know about the location of mounts, on either the engine(s) or drivetrain components, so I can't comment on that - beyond saying I'd be very surprised if the larger stuff simply "dropped in".

I would also advise you to swap both the front and rear diffs.

I don't expect such a swap would be an easy process, but if you do it well, I believe you would be very happy with the result.

[roaming knome]

Hello Scott,

Thanks for the info. I have been searching high and low for any information on the Delica 4M40 swap, because one happens to be available to me right now. The 4M40 engines are pretty rare here (Pajero/Delica)
I plan on installing a minor lift of 30mm possibly 50mm but I don't want to go any higher than that. I already have front and rear axles as I am going to convert the front to solid axle as well. I chose to use Toyota FZJ-80 axles since they are only a few inches wider 62.5" WMS to WMS opposed to the Mitsubishi 58"and I also get to upgrade to disk brakes and full floating in the rear. The front also has the large 4 piston calipers. They also happen to be the E-locker type as well!
Some of the info I have come across is that the engine block and maybe head are the same between the Pajero Delica but components such as injector pump intake/exhaust manifolds and glow plugs are different. I am wondering if these components have significant differences to cause problems with the swap. The seller has confirmed the it is a mechanical pump engine, so no electronics.
I also need to know if the oil pan is a front or rear sump pan as I am going to need a rear sump pan to clear the front axle.
I just want to get all the info I can to help the ease of this process, even though it is not going to be easy!
Any and all info is greatly appreciated!

Thanks,
Adrian.

[roaming knome]

This is what I have done so far. It's going to use 1-1/4" rod end bearings and the links are going to be 2" x .25" wall chromoly tube

[NJV6]

Alot of the Delica's had the oil pump/cooler/filter setup in a different place to the Pajero so I know a Pajero engine cannot go into a Delica but not sure about the other way around. The parts can be made to swap but you really need both engines there to know where to drill the extra holes into the block etc.
It was a swap i was considering when I had a 4M40 pajero that was broken, but to fit the 4M40 Delica engine was technically above me due to the mod's req'd.

[roaming knome]

Hello NJV6,

Thanks for the info! It is very much appreciated. I would have liked and preferred to use a 4m40 from a Pajero but they are extremely rare here. I guess I'm going to find out soon as the engine is on its way. I will keep this thread updated as I'm sure I will need advice/info on this engine. It is a challenge but not impossible.
I'm also impressed with your project chop! Great project and rig!

Adrian.

[toastmaster]

Not that it's the same at all but swapped in a 4D55 from a L200 into my '88 SWB Montero. It was a pretty simple swap, I only had to change the oil pan to a rear sump which i got from a Ford Ranger 4D55 and modify my air cleaner otherwise it was a direct swap. I'd suggest maybe holding out for a Pajero or L200/Challenger 4M40 because you might spend more time and money finding parts to make the Delica motor work but on the cool side the Delica has fixed yokes on the T-case.

On the 80 series axles are you going to "flip" the front axle to be driver side diff or are you going to run a passenger side T-case like a D300 or something? I built a Np231/D20 dual case setup and it was only slightly longer than the 4 cylinder mitsu T-case and almost 7:1 low range. Something to consider.





And if you get the shifter boots from a truck with a 5 speed it makes the dual shifters look factory (except i configured for triple sticks 2 for shifting the D20 and one for the Np231 so that i can have 2wd low low, and if you modify the rail on the D20 you can have front wheel drive, front low and front low low)

[roaming knome]

Toastmaster,
I was thinking of running dual cases down the road, however it is very tempting and I really like the look of the twin stick shifter.
I actually already got the Delica complete engine swap (4m40, auto trans, t-case, wire harness, and other odds and ends to help the swap more complete). It should be arriving next week sometime.
The Delica is a RHD vehicle and my Montero is LHD. The stock Delica t-case is passenger drop This is one reason why I chose to use 80 series alxes, so no need for the front axle flip. I already have my axles and will start to strip them down for spring and link bracket welding.
Right now I am currently trying to track down a rear sump oil pan, but am finding the process to be quite challenging. Hopefully I will find one soon or I will most likely have to modify the stock one. First things first, I am going to focus on getting the engine in and operating which is going to take some electrical engineering, and decision making because the Delica 4m40 is a 24volt system and Montero 12volt system. so current dilemma is do I keep the engine 24volt and get a converter or do I convert the engine to 12volt, or do I convert the whole Montero to 24volt. I am going to have the complete wire harness from both vehicles so I am just going to have to decide which way to go.
Was the 4D55 engine you used 12volt system? I really like the idea of dual cases and what you have done to your Montero/Pajero, do you have a build thread on your truck?
Thanks for the info!
Adrian.

[toastmaster]

http://www.4x4wire.com/forums/showflat. ... page=&vc=1

I haven't updated it in a while, But i have changed some things on the build. I traded my friend my dual case setup for a automatic transmission with like 80k miles and a single speed Marks 4wd crawler case. Also got a Montero sport axle with factory air locker in it now. But back to your project Maybe you can get the 12v cutoff solenoid for your 4M40 and you can most likely run all the gauges. Oh and i'm sneakyninja on Pirate4x4.com

[roaming knome]

OH, I have read your build before,
Nice work!
I'm now looking for a right hand side t-case because even though the t-case from the RHD Delica is left side drop I need one to be on the right side.
I assumed wrong. I would like to be able to adapt an fzj-80 case on there since I am using the 80 series axles. However it would be cool to be able to use a doubler set up with the D300 and twin stick shifter's.
I'm trying to do some research but not much comes up on the Delica auto trans, so I'm just going to wait until it arrives and do some measurements. I'm sure the auto trans from the 4m40 is different from the 4D56 as well.
I think I'm going to set up the electrical system with the converter as well, thanks!
Just too much to convert everything to 24 volts.
Thanks for all the help Toastmaaster!

Adrian.

[Lordtrunks]

you can swap in a dana 300 which is right hand drop to match your toyota axle diff you'll need a transmission tailshaft housing off a jeep aw4 and the 4 prong pulse ring to go with it the pulse ring needs to be counter bored to the depth of that of the mitsu pulse ring its pretty soft material any machine shop can do this for you. let me know if you need anymore info or pics on what i'm talking about.