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Thread: Out with the old and in with the new....

  1. #1
    Join Date
    Jan 2010
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    Brisbane, QLD.(Formerly Port Lincoln, S.A.)
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    Out with the old and in with the new....

    After much misery with the 4.0 i finally got approval from the minister of finance to replace it with a new powerplant (the fact that it pressurized the cooling system and cooked while she was driving it helped my case to no end ).
    After shopping around i ended up purchasing a top hatted high compression 4.6 long motor fitted with a high lift cam - all courtesy of TRS in Adelaide.
    I'm about to do the changeover myself and was hoping for any advice from others that have already done this conversion.
    The guys at TRS supplied me with a new thermostat and the radiator is off being flushed and inspected, i have heard stories about oil pump priming issues and was wondering if anyone can outline the procedure for a) inspecting and greasing the pump and b) manually priming the pump.
    I'm also chasing a workshop manual - its a 2004 D2 4.0
    As always any help greatly appreciated.

  2. #2
    Join Date
    Oct 2003
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    Montrose, Vic.
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    G'day Redslayer,

    I haven't done the conversion myself so can't be much help there - but as far as a manual goes the best option is to visit the shop link at the top of the page, it will take you here:

    Dave's Interesting Things

    Sounds like what you need is Rave II and the cost of the disk I believe goes towards supporting this site.

    Good luck with it.
    Mark

    Of all the things I've lost, I miss my mind the most

    2015 TDV6 D4.... the latest project... Llams, Traxide, Icom 455, Tuffant Kimberleys and Mofos.... so far.
    2012 SDV6 SE D4 with some stuff... gone...
    2003 D2a TD5...gone...
    2000 D2 V8...gone...
    https://bymark.photography


  3. #3
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    Jan 2010
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    Quote Originally Posted by Bytemrk View Post
    G'day Redslayer,

    I haven't done the conversion myself so can't be much help there - but as far as a manual goes the best option is to visit the shop link at the top of the page, it will take you here:

    Dave's Interesting Things

    Sounds like what you need is Rave II and the cost of the disk I believe goes towards supporting this site.

    Good luck with it.
    Cheers for the help Bytemrk, Just wondering if anyone else out there can confirm that the Rave II covers the 2004 D2 4.0 - If i'm reading it right it says D2 V8i 1996 on to 2003 - IF i'm reading it right

  4. #4
    Join Date
    Feb 2009
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    Newborough, VIC
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    Yep,
    RAVE II is the one you want.
    2002 D2 4.6L V8 Auto SLS+2" ACE CDL Truetrac(F) Nanocom(V8 only)

  5. #5
    Join Date
    Dec 2007
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    Sydney, you know. The olympic one.
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    Only difference I came across was the crank angle sensor is different from the 4.0 D2 and the 4.6 from a P38. The only solution without buying a new CAS is to swap the plate over that is welded/pinned into the block. It's not a big job. Just careful with a grinder and then drill and pin the original one back into place. Not sure if the P38 CAS is the same plug as the D2.

  6. #6
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    Quote Originally Posted by clubagreenie View Post
    Only difference I came across was the crank angle sensor is different from the 4.0 D2 and the 4.6 from a P38. The only solution without buying a new CAS is to swap the plate over that is welded/pinned into the block. It's not a big job. Just careful with a grinder and then drill and pin the original one back into place. Not sure if the P38 CAS is the same plug as the D2.
    Cheers for the tip mate, spoke with the guys at TRS before ordering the new donk, told them it was going in a post 99 D2 so they set the CAS plate up to suit for me. I tell you what, these blokes are bloody great to deal with.

  7. #7
    Join Date
    Jan 2010
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    Just an update on how things are progressing so far......

    Its been an absolute mission doing this engine changeover on my own, is it just coincidence that we leave it just long enough between projects like this to forget how painful they are or what?
    What seemed like a 2 day job has dragged out to 4 now with a few little speed bumps along the way to slow me down.
    Lessons learned so far include;
    changing rocker cover bolts from ridiculous double hex items that are painful to get to (all my deep sockets are single hex) to recessed hex key/allen key items.
    Leaving sump off until after dropping the motor in so that flywheel/torque converter bolts can be accessed easier - the tiny hole LR give you is a joke.
    remove plenum chamber from inlet manifold before removal of engine, despite what RAVE says it makes it so much easier to get to top bell housing bolts and lower coil bolts - oh yeah i'd love to meet the guy who decided to put the ignition coils at the back of the inlet manifold
    Other than that it has gone reasonably well without a hitch so far, wouldve been finished thisafternoon had it not been for a couple exhaust gaskets and a cooling hose i forgot to buy yesterday - all things going well should be hitting the key tomorrow before lunch - cant wait to hear this thing run i dont think ive slept properly since i started this job......

  8. #8
    Join Date
    Jan 2010
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    Well today was D-Day, finally got the few little bits and pieces i needed to finish up before hitting the key.
    Finally got to fire it up and..........
    ITS ALIVE!!!!
    I pulled the fuel pump fuse first and cranked her over a few times to prime the oil pump before running the motor, replaced the fuse and away she went.
    Its a little disconcerting running a fresh motor at 2500rpm straight away but that was the recommended procedure from TRS to bed in the camshaft so who am i to argue. 20mins later dropped it back down to idle and what a sweet sound!
    Took her out for a test run around the backstreets and she ran bloody beautifully!
    back home for a celebration beer whilst admiring my handywork and wouldnt you know it - there's a strong smell of fuel..... after a quick look under the bonnet i found a pool of fuel on the inlet manifold coming from the top O-ring on the No.1 injector
    So it looks like the plenum chamber is coming off again to overhaul all O-rings on the injectors.... kicking myself for not doing it during assembly but i spose it couldve been worse...
    Another valuable lesson learnt - do it right the first time!
    I actually told myself i should be changing out the o-rings when i had to remove the injectors to get the torque wrench on the inlet manifold bolts but ignored my own good advice...

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