Hyundai D4BF engine install

Does your Mitsubishi L300 make a strange noise? Need wheel alignment specs?
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Growlerbearnz
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Hyundai D4BF engine install

Postby Growlerbearnz » Wed Oct 11, 2017 10:22 pm

joebillhill wrote:Woo! Nicely done growlerbear! I'm curious how your tachometer troubleshooting goes as mine is about 1k slower than it should show all the time


Mine did that for a while. turns out the needle had slipped on the shaft- with the engine off the needle should sit on the lowest mark, not off the bottom of the dial. I pulled it off, applied some thread locker, and reinstalled.

Though I'm probably going to have to pull the needle off again soon.
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Hyundai D4BF engine install

Postby Growlerbearnz » Wed Oct 11, 2017 10:34 pm

...And it drives!

First impressions: it idles really smoothly, and it's much quieter than the old engine. Something to do with the pistons going up and down rather than side to side I think ;-). The diesel clatter stands out as the loudest noise it makes, where before it was about as loud as the general mechanical cacophony.

It's been a long time since I drove a stock L300, so I don't know if it's more powerful or not. As it was supplied it made 8psi, produced no exhaust smoke *at all*, and the lowest air:fuel ratio I saw was 25:1.

Of course I'm fixing all that. I'm up to 17psi, 18:1 AFR, and still only a touch of smoke on acceleration, and it's *much* better. I'll keep working on it.
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Hyundai D4BF engine install

Postby Growlerbearnz » Thu Oct 12, 2017 4:57 pm

Tachometer issue resolved!

The black wire from the sensor on the IP needs to be connected to earth. On Mitsubishi's engine this is done in the short IP loom, before it even gets to the IP connectors. Hyundai does it elsewhere. Simply remove the Hyundai IP loom, find the two black wires (tachometer sensor earth and IP earth) and connect them together.

:-D
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Hyundai D4BF engine install

Postby Growlerbearnz » Sun Oct 15, 2017 11:57 pm

And the final touch: new drivetrain mounts all round. The old engine mounts were badly collapsed, the transmission mounts had splits, and the upper transmission mounts were very saggy.

Mounts.JPG
Mounts.JPG (51.53 KiB) Viewed 413 times


New mounts have made a huge difference. No more knocking noise when turning the engine off, vibration at idle has almost disappeared, as has the slight shudder on takeoff. :-D
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Hyundai D4BF engine install

Postby Morgonzo » Mon Oct 16, 2017 5:19 am

That's some inspiring stuff GBNZ :-D . It's crazy to see how much those old motor mounts had compressed. How long do think this swap has taken you from start to finish?
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Hyundai D4BF engine install

Postby Sylquebec » Mon Oct 16, 2017 9:48 am

Thanks for that post. Really inspiring

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Hyundai D4BF engine install

Postby Growlerbearnz » Mon Oct 16, 2017 1:04 pm

Morgonzo wrote:How long do think this swap has taken you from start to finish?


The engine swap took 10 days total, though it probably would have been faster if the van didn't have quite so many modifications.

I'd budget 2 days to remove the old engine, 3 days to swap all the bits from the old engine onto the new one, a day for cleaning the engine bay and flushing out the radiator and oil cooler, and a couple of days to install the new engine.
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Hyundai D4BF engine install

Postby Growlerbearnz » Tue Oct 24, 2017 1:58 pm

Update at 800km:

The engine's character has changed as it breaks in. Idle is now ridiculously smooth and quiet, and it sits at 750rpm whether cold or hot. It responds to the throttle quickly, and revs to 4100rpm without sounding breathless or thrashy.

Coolant temperatures are stable- about 1/3 on the gauge, moving up to 1/2 when towing a caravan up a steep hill for 10 minutes (where the old engine would have been at about 3/4 or higher).

Exhaust temperatures are 200F/100C lower than before. About 750F/400C cruising at 100kph. The highest I can provoke is 1200F, where the old engine could go above 1400F if I let it.

The new breather oil separator (ProVent 200) is completely, utterly dry. Zero oil is coming out the breather (Hooray for Hyundai's improved oil separator in the rocker cover, I guess).

And the best bit: Still no oil leaks!

Edit: an hour after writing this my automatic gearbox failed. Whoops. Maybe I'll turn the power down a bit.
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Hyundai D4BF engine install

Postby archieim » Thu Oct 26, 2017 5:47 pm

Can you throw a cost value and time
Approximate....



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Hyundai D4BF engine install

Postby Growlerbearnz » Thu Oct 26, 2017 6:54 pm

I've mentioned it in previous posts, but TL:DR; it took about 10 days (less on a regular, unmodified van) and the engine cost about CAD$5800 shipped to New Zealand.
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Hyundai D4BF engine install

Postby lrp374 » Fri Oct 27, 2017 9:03 am

Growler I know you have gauges for everything!! What is your range for oil pressure?

Thanks

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Hyundai D4BF engine install

Postby north54 » Fri Oct 27, 2017 10:02 am

Growlerbearnz wrote:The new breather oil separator (ProVent 200)


Where did you install your Provent? I think you saw I had mine in the air breather box compartment under the driver seat.
TRUSTY RUSTY

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Hyundai D4BF engine install

Postby Growlerbearnz » Fri Oct 27, 2017 2:44 pm

lrp374 wrote:Growler I know you have gauges for everything!! What is your range for oil pressure?


Everything... except oil pressure. Sorry.

north54 wrote:Where did you install your Provent?


Yup, same as yours. And you were right- finding room for 25mm pipes was a nightmare! I ended up cutting a new hole for one of the pipes (below the wiring loom hole), and routing them both below the glow relays and around the air box.
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Hyundai D4BF engine install

Postby north54 » Fri Oct 27, 2017 6:27 pm

Hmmm keep in mind I didn't see any oil in the reservoir until after around 1000km of use. It takes a bit of time for oil to travel through those long hoses. It definitely did its job and collected oil eliminating a lot of leaks around the turbo.

I then had a bad oil leak up north where oil was leaking out of the dipstick where it sits in the block. I figured it was due to excess pressure from the long hoses, like you forewarned. I removed the Provent for now till I can find a spot closer inside the main engine bay.

Sounds like you may not even need it anyway with the new engine!
TRUSTY RUSTY

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Hyundai D4BF engine install

Postby lrp374 » Tue Nov 21, 2017 9:48 am

Good Morning Growler - I've got a couple of questions about your new motor:
1. You've indicated you're now running about 17 psi. Do you have any trouble with that pop-valve ( or whatever it's called ) operating or have you disabled or replaced it?

2.Is the waste gate adjustment rod the same as the old engine?

3. Did you need a different lower rad hose because of the angle of the water pump?

4. Did you need to do any external connections to the watercooled turbo?

5. Is it still shiny?


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