PLEASE HELP!! 4M40 replacement

[retz_jero]

hey people, im a little over 16 and a half. i Just brought a 1994 NH(i think) 2.8 turbo diesel intercooled. From what i understand the 4m40 engine is much similar to the 4m41 big brother. injection different and compression and stuff. BUT i really want to put a 4m41 engine into the engine bay. Currently no engine in it! the 4m40 was completely and utterly buggered. So i have a few months before i get my liscence and i have sum weekend to spedn doing the conversion. i would muchly appreciate any information anyone has, and anyone who knos somebody who has attempted this conversion whether it be successfull or not.

If its any consolation it already has an awsum sound system!!

Rhett

[-Scott-]

Hi Rhett - welcome to OL.

Your 4by is NJ - the first to receive the 2.8. I have heard that the 2.8 and the 3.2 have the same block, so the swap should be relatively simple.

I don't know anybody who has done this, but there's no reason it can't be done successfully.

Take pics and post up!

Scott

[retz_jero]

hey man thanks, i dont take much interest in the model numbers, just year and shape and engine etc etc. i have engine manuals for both the 4m40 and 4m41, and from the pics of the driveplates, they look identicle. and i want to keep my old gearbox as it is near new or been reconditioned. mm nice and tight shifting. but from what i have noticed the new 4m41 has a soft clutch and the old doesn't, and im thinking of whether or not this would make any difference.

rhett

[Bitsamissin]

From what I can gather the 4M40 basically has the same block as the 4M41. The 4M41 has a 16 valve DOHC head with the EFI fuel pump.
So the 4M41 should bolt up to your existing gearbox on the original engine mounts. The hard part would be sorting out all the EFI wiring and ECU. But no harder than a petrol EFI conversion.
There is a guy on the forum from South Africa that has dropped a 3.2DiD into his Gen 1. Try doing a search.

[Ian Sharpe]

Hey Frank,

Given that it appears the 3.2 will mate with the 2.8 gearbox & that 2.8TDis were available overseas in auto form, it seems probable that the 3.2TDI would also mate to the 3.5l manuals & auto boxes.

What do you think???

cheers

[retz_jero]

hey guys, THANKS HEAPS FOR THE INFO. all i need now is a source, of any type of available engine., im desperate now. lol 3.2 would be very lovely!! thanks again guys. gen 1? with 3.2 is that the older shape? im very curious bout this. where is the injection pump located on a 4m41 car? on the engine or seperate? and any info on an engine ? where to find or get? thanks, rhett

[Bitsamissin]

Ian, the 3.2 DiD uses the same 5sp as the 3.5 V6 / 2.8TDI. I'm not 100% sure on the auto as the DiD uses the Invecs 2 5sp auto and I'm yet to confirm the output shaft size and spline count. Going by Mitsu t/case input gear part no's they are the same but I'd still like to physically check.

Attached is a 4M41 factory workshop manual (2.5Meg) :-
http://members.austarmetro.com.au/~fran ... Manual.pdf
And it looks like the injector pump is in the same location as a 2.8TDI.
You can try local wreckers for these motors or it maybe more economical to import a half cut from an import wrecker.
Here is the thread with the 3.2DiD conversion (check the last post) :-
http://www.outerlimits4x4.com/PHP_Modul ... hp?t=46898

[4ePajero]

Hi guys, I am the pioneer (with my two brothers) who are building DiD (4M41) engines into the two GenIs and one GenII.

A few facts, after reading this thread:

1. Engine blocks of 4M40 (2800 TDi) and 4M41(DD) are similar (identical in most respects).

2. The Bell-housing/transmission does not bolt onto the engine, but onto an adapter plate which is bolted to the block. Most (all) late model transmissions should thus work, even if it requires a special adaptor plate.

This photo shows the block from the rear, with the adaptor plate (and flywheel) removed.



This picture shows the flywheel and adaptor plate (for the V5M31 5-spd transmission) fitted.



3. The injector pump can be seen on both photos.

4. Don't tackle the project if you can't (or have access to someone who can) manufacture things like mountings, brackets etc.

4. The building in of the engine is no great problem, but the difficult part is the electrics & electronics. If you buy an engine etc., I would recommend getting getting the entire drivetrain (engine, gearbox and transfer case), peripherals and complete wiring looms with the electronic components from the same wreck.

5. I don't know about your legislation regarding engineer's certificates etc., so keep that in mind. We are fortunate not to have such requirements.

6. Here is the thread on our local forum where this project is documented:

http://4xforum.co.za/cgi-bin/YaBB/YaBB. ... 1110265157

7. It cannot be justified from a financial, but only from an emotional perspective!

[-Scott-]

7. It cannot be justified from a financial, but only from an emotional perspective!

Of course - it is a fourby, after all!