L400 3.8L Mivec 5spd Sportronic w/Paddle shift

[VR Trooper]

I've got a '96 L400 LWB Super Exceed 3.0L Petrol, that I bought in 2012. I've been doing extensive mechanical mods to it and wanted to share it with members here.
I hope this thread will be informative and I appreciate any input/feedback. I wouldn't have been able to accomplish my goals so far, without the help of people I've met on other Mitsubishi sites.

A couple weeks after buying My L400, with only 2000km in the seat, I had some engine issues and ended up with 12 bent intake valves. The dealer in Richmond that I purchased it from, told me to take a hike. (PM inquiries welcome).
Eventually I got tired of taking 2km to pass a semi on the highway, so I decided that throwing a 265hp 3.8L Mivec engine from a 2007 Eclipse GT would be a good solution.
While working on the engine swap, I started to realize that a Pajero/Montero 5spd Sportronic transmission might be a do-able upgrade. So I started searching North America to chase down a donor. After 6 months, I located one in BC and raped an '03 Montero for everything I could grab. Transmission, Diffs, Electrical, Interior, Brakes, etc. There wasn't much left on the poor chassis.

Trying to modify everything I want will take years, so I figure I'll do it in stages.
I should've started posting here sooner. I've mostly been posting on the Delicaclub.com and and Eclipse club4g.org.
It's been a real challenge so far, and I have had it running. But after a couple setbacks, she's back apart awaiting some repairs. Back ordered engine parts just arrived after six months, and my work schedule will hopefully let up this spring so I can get her back on the road.

I do wish I'd started posting here when I started the project. I guess I'll be playing a bit of catch up. I may copy some of the posts from the Aussie forum.

Please PM me if any images or links in this thread are broken or don't display.

[pinkiep]

that is a mean looking van , love the LWB.

[thelazygreenfox]

Wow, that'll be an exciting L400 to drive when you're finished. Too bad the original valves were out of time. Or did the belt break?

Where are you located?

Did you install the electronics and computer from the Mivec to the L400? Was the engine/transmission mate an exact fit or was machining needed?

I have an 95 L400 2.4 litre and had thought of installing a turbo but all that I've read says this is not the engine of choice for the install. Good engine but later versions are better.

Welcome aboard our site, hope to hear more later.

Wayne
TLGF

[Big-Bird]

This is gonna be like the Lexus/Toyota V8 powered deli across the pond. That thing is angry!

[VR Trooper]

Hey guys, thanks for the welcome.
This Deli spoke to me when I was looking. Too bad I got shafted by the dealer after buying it.
Something failed in the new timing belt it had and bent the valves. $3k+ in mechanical damage.

I did swap in the full Eclipse engine management system w/multiple wiring harness and relay panel. Used Eclipse tuning software to eliminate the security Immobilize. (That took months of cursing, sleepless nights, as well as assistance from Mitsu guru's in OZ, NZ , US and Russia)
I pretty much went blindly into this swAp, unknowing if the engine would mate to the transmission. I found a great deal on the engine, ordered it up and hoped that my online research was adequate. I'd investigated any documentation I could find. Cross referenced people who'd put engines or transmission into different vehicles. Assessed bell housings and block configurations and images, determining that my chances were pretty good that it would mate. And it did. Perfectly. No machining, but some assembly required...

I think the 2.4L is a solid engine, although I don't know a lot about them. The 3.0L is rock solid, provided you don't have a t-belt failure. lol...
The newer 3.8L engines are capable of nearly 500hp on a stock bottom end. Some people are trying to achieve 700+hp with built up engines. Not that a Delica is in need of that much HP.

Yup, 4 z bch on Delicaclub.com has a V8 Supercharged Toyota powered L400. Mean Beast! Nice guy...

I'm located in Northern BC

[VR Trooper]

Here's an ongoing list of modifications, parts, part numbers and other details required for this transplant in case it helps anyone in the future. I'll keep adding to it as I go.
These are USDM Mitsubishi components from G4 Eclipse, L400 Delica, 3.8L Challenger (Montero Sport), Endeavor and maybe other models.
Updated - Feb 3 2013

Parts:
Engine - 3.8L Mivec 58K Km from recycler in Vancouver BC.
Wiring - Eclipse engine harness, front chassis harness, dash harness.
Fuel - Fuel rail from early model 2004 Endeavor 3.8L (thru - 12/03)
Accelerator Pedal - From Galant/Eclipse
Coolant - Rear cross over pipe from Pajero, Modify coolant return pipe
Intake - DC Sport cold air intake from Eclipse GS '06-11
Exhaust - OBX Headers for 90-95 Pathfinder chinese cheapies but $142 US shipped (requires custom flanges), Custom Stainless Steel 2.5" mandrel bent exhaust system (to be installed)
Transmission - 5spd Sportronic - (Purchased and waiting - paddle shifters are waiting)
Paddle Shifters - Test fitted and mounted. Mounting plate is larger than Delica column covers requiring some magical solution - still to be created.
Propane System - Landi Renzo, Twin under chassis tanks 130L (in place of spare tire),

Fabrication:
AC compressor mounting bracket - Clearance,
Dip stick tube - Reroute,
Engine mounts - Fab'd and lowered,
Cylinder head (shave for clearance at firewall),
Coolant return tube (reshaped for Mivec oil valve housing),
Coolant cross over pipe (18mm spacer installed),
Coolant flange spacer @ upper rad housing,
Timing covers,
Endeavor fuel rail & pressure regulator adapter,
Upper intake manifold (clearance for firewall, Relocate MAP sensor)
Lower intake manifold (clearance for water pump housing)
Accelerator pedal mounting bracket,
Transmission kick down cable actuator (Eclipse is DBW) - Made a temporary fix,
Intake ducting,
Remote mount Mivec oil valve housing,
LPG propane system & tanks,
Trailer hitch,
Paddle shifters,

Wiring harness (shortened and lengthened some wires, reloomed)
ECU & Relay panel mounting brackets,


Other topics to be added as I remember them.

[Mr. Flibble]

I have been watching your build on the OZ forum and I am glad to see you put it here too.

[VR Trooper]

I ended up posting there for a number of reasons, and once I started I was so busy working on Project Delica, that I didn't have much time to post elsewhere.
Its too bad max image size is 960px. I have to modify all the images I have on photobucket. Since waiting so long for parts and not working on it in the meantime, I wanted to get a thread started here, before I dove back into the build.

[VR Trooper]

Here are some pics of my Dilema...


Day 5 of my new ride!




My Baby at Work...




Day 2 beginning of my road trip home... Dropping my 17x9" rims w/265/65-17" Nokian Vatiiva's

[VR Trooper]

Here's a shot of my intake valves after a timing belt failure, and pulling the engine. Ya, I realized pretty quick its an interferance engine...



And some pics of the engine swAp:

Engine arrived 3pm... Tuesday...






Engine at 3:30pm... Tuesday...
I swapped the valve covers left for right, and mounted the intake manifold 180 from original position.
This allowed the throttle body sit near the radiator, instead of through the firewall.



Test fitting component layout 4pm... Tuesday...




Mock fitting intake and V/C's in engine bay... 5pm... Tuesday




Fitting water pump housing...




Mounting Accessory drive mounting plate...




Dirty old 6G72 components...




Old 3.0L removed...




Think my Deli's bleeding... or crying...




empty engine bay, nothing new...




Mock up mostly complete, minus a few parts...




Man those are some high flowing OE manifolds!!!




6G72 Backing plate




Couple conflicts in this mock up...

[VR Trooper]

Coolant return tubing, had to be reshaped around the rear cross over pipe and the USDM Mivec oil valve. (different unit than JDM/ADM)
Had to remove the 6mm tube for the no-longer-needed throttle body hose.




Clearancing the backside of the left bank cylinder head. The shape matches the original 6G72 shape (which cleared the firewall of course). I shifted the 'shape' 19mm closer to the block due to the taller 6G75 deck height.




Pretty evident, but the cardboard cutout represents the shape of the firewall and is assisting in reducing the number of times I need to install and remove the engine.
The cam sensor wiring connector will be an issue as will the right bank Mivec oil valve housing.
With the valve covers and intake mounted in reversed from the OE position, the original timing cover mounting holes are now facing the firewall, as are the timing marks...
Part of which needed to be ground off for clearance. No turning back from that one!

[VR Trooper]

Tore into the engine work and completed a few modifications.
Coolant mods, Timing Belt covers, Engine mount bracket, Wiring, Fuel rail, V/C breather vent, etc.
I think I'm just getting over the 50% hump!
I also practiced removing wiring pins from their plastic connector housings. I managed to remove nearly every style of pin in both the Deli and Eclipse harness'.


Thermostat housing spacer: 13mm







Rear coolant cross over pipe:



Coolant return tube: Reshaped around cross over pipe and Mivec housing (Tried running it below the cross over line on first attempt, tube got kinda ugly after the second 'Adjustment'.

[VR Trooper]

Engine Mount Bracket: Right Side
The upper two bolt holes are missing the threaded bosses.






Plates made and ready for welding

[VR Trooper]

Timing Covers:

Drilled spot welds off original valve cover




Mounted a couple of tabs on the ends and painted 'er up




Cut up the Eclipse center backing plate




Made some mounting tabs




Mixed Eclipse plate with the original Deli backing plate




Hacked up the Eclipse cover and the new 3.8L Challenger/Montero Sport upper timing covers, and morphed the Eclipse mounting hole onto the Montero Sport cover.
(likely unnecessary for JDM/ADM models)




Dug out my old plastic welder from my VW/Audi days




Not my best welding job ever...




Test fit after custom work




Tab to locate the lower cover




Shield for a gap area exposed from the shorter Eclipse front main seal housing




Shield installed before paint

[VR Trooper]

Drive by Wire accelerator pedal bracket:
Mounted to pedal assembly without destroying the original Deli accel pedal mounting bracket