OK, Toasty, I figured out how to fix my Ubuntu issue. I was logged in to the site but somehow when I tried to post on the bbs it thought I was logged off. I went to my profile page and "expired my cookies" (sounds like something you'd only need to do after a long night of drinking beer). Then it let me log in from scratch. Strange...

4e: Thanks!!! How did I miss that? Will be studying this one for sure...

Kane: thanks for the SWB/4D55 review. Very helpful. Sounds like I need a little more power.

Spence: I think we have a winner. 4D56 sounds like too much work for the reward. Maybe just the basic 4M40 N/A model would be just enough power and get me closer to that 30 mpg fantasy. Sure would be nice to have the 220ft lbs of torque when I needed it though. You said stock transmission could handle the 4M40's torque? I like the idea of buying a wrecked or half-cut in order to have the whole drivetrain. My transmission is in nice shape but I wonder if I would even save anything after all the extra work to mate it to the 4M40...

Phil: Thanks for the real world fuel economy figures. Hopefully I'd do a little better between the lighter Gen1, stock tires, more highway driving (I use my Montero mostly for long-range canoe / camping trips). Yours and Spence's description of the 4M40 makes me really think that would be a great fit regardless of the swap compatibility.

I'll be gathering info for now over the next few months and will plan to drive the Monty as is in the meantime till she takes a dive. Then I'll be ready when that happens.

Very Very Thank You folks!

-Ray

Phil wrote:


I agree 100%.
I don't like transplants which have adapters between engine and transmission.
The cost of the 'large' stuff is quickly over-run by the costs of the 'small' stuff.
If you have a wreck, you save on sourcing / manufacturing all those additional items.

I know the Mitsu 4-cyl diesel engines and if the 3.2Di-D is rated at 100, I would rate the others as follows:

3.2 Di-D (4m41) 100
2.8 TDi (4m40) 65
2.5 TDi (4d56) 25

I never liked the 2.5 TDi (with which I bought my Gen1). Heavy on fuel if worked hard, and slow.

Beware the 4m40. They crack heads!
If you fit this engine, fit the largest & best radiator you can fit (3 rows).
I fitted two oil coolers (the in-block standard one as well as an external one).
Fit an EGT gauge, to monitor combustion temps (to protect your head).

Good idea on keeping the original oil cooler, too. I wonder if a non-turbo 4M40 might be better about overheating. Think I'd be disappointed with the power? (I'm content with the power of the original V6 gas).

Man, your Pajero is BEAUTIFUL! And tough-looking, of course...

Very very impressed with your job.

After looking at your writeup, I wonder about the RHD vs LHD issues that might pop up (mine's a LHD). Seems like an auto transmission might be better for me so that all I have to line up is the throttle. Or is it easier than I might guess to make a manual work?

So you needed to lift the body 2" to get the 4M41 to fit, even with fitting the intercooler on the front rather than on top of the engine? And you had to fab new mounts. Is the 4M40 that much different a footprint than the 4M41? I was thinking you meant in your earlier post that the motor mounts on the 4M40 were identical to the V6 gasser on the Gen1. That would be too easy wouldn't it? <img src="/forums/images/graemlins/smile.gif" alt="" />

the 4m40 NA is slower than a snail - I would not.


Thanks!



Gen2 clutch pedal and master bolts straight onto chassis!




Not quite a necessity, my brother did a similar transplant without the lift. It is thus possible, but the lift just makes it so much easier.



Mine had a 4d56 engine (originally), and then a Chevy 4.3, so the mounts were non-standard. I manufactured new ones, which is easy. I don't know whether the V6 and 4m40 mounts are identical, but I would be surprised if they are.


The 4m40 and 4m41 blocks are virtually identical. The heads differ substantially, though.

Good news! I would think you'd at least have to turn the gear box around or something to get things aimed at the left side...



2" sounds reasonable to me. I found a great write up in the FAQ section.




Good point. You don't really have a frame of reference by the time you got to the 4M40



Homework time.

Thanks very much for taking the time to respond. I've started a parts / required mods / potential hiccup list. Hopefully I can contribute in my own way with a write up of this project.

-Ray