Engine swap T4 2.4 diesel to 2.5 petrol

[Sunny43.5]

Hi all after some serious soul searching have decided to remove tired diesel donk and fit 2.5 petrol to my sons T4 . Have bought whole van with all running gear so no shortage of parts to swap over . Question how the bloody hell do you lower the engine from the van ? after disconnecting every thing and putting van on jack stands it seems like the engine wants to tip over when we start lowering it . Would it be easier to remove the main crossmember bumper support where the radiator attaches so we can roll the engine out in a forward direction ?????????? Thanks in advance for any suggestions Howard

[Seano]

Yes.............

[Sunny43.5]

Yes............. Yes you were right its a pity the bloody manual we had did not give us that option ,the book says to use a trolley jack to lower it ,I had doubts that the engine would even fit under the front bumber even on stands so we decide ourselves to remove the front section and bingo the whole motor was exposed . If I had know that from the start we could have removed the engine hours earlier with out all the cursing and skinned knuckles .Jeeeeez . Thanks any way Howard

[Sunny43.5]

Okay heres my update on our current project .Bought T4 van with donor 2.5 motor the shell was totally stripped bare except for engine no ecu dash etc no doors brakes nothing . Well after stuffing around for two weeks trying to source the extras needed for the change gave up in disgust no ecu no dash nothing was available from dozens of wreckers . A T4 turned up on Ebay which we bought a complete running road registered 2 .5 petrol travelled from Brisbane by train to Coffs Harbour and drove it home same day . We were really lucky the engine is in really good condition so I am in the middle of doing the change no problems so far will update when finished .

[Sunny43.5]

Finished changeover complete what a job .Regards Howard

[jets]

Did you think to take any pictures during your operation, I would love to see them.

[Sunny43.5]

Unfortunatley the only photos I took were of the fuse box from each van to make sure the relays went in the correct places , marked all the wires so as each new plug was reconnected the plugs went into the appropiate connection . The instrument binnacle was a breeze just a couple of screws to release unplug and screw back in . As for the actual change over it went quite well change over the exhaust fuel tank and fuel lines etc , worst part of that job was the petrol engine has a different plug and wires to the fuel tank so had to remove inspection cover in floor and remove one harness and change to the other . change over charcoal cannister and lambada probe was easy , hardest and time consumming was reconnecting all the water pipes airco pipes and power steering pipes . I replaced the water pump and cam belt with tensioner whilst engine was out . After refitting and checking everything I held my breath when I turned the key for the first time held it on for about 5 seconds no start tried second time another 5 seconds no start , third turn the engine sprang to life after just 2 seconds I was stoked [probably took time for fuel to refill the lines etc ] . Only drama was no temp reading and the oil light would start flashing with warning buzzer when a few revs were done , pondered for a while and went back and checked every connection , pulled fuse box down again started the van and touched something and the light went out and temp gauge sprung to life [hadn,t pushed one of the plugs in the fuse box in properly ] End result my son is very happy now the van goes so much better with the petrol engine pulls strongly , I suspect that a previous owner of the van the engine came from had done it up because I don,t remmeber my 2.5 I had back in 2000 going this well , for instance we live on the top of a very large hill with along steep climb the best my 2.5 could do from a stop start at the bottom of the hill would be about 40kph in 3rd at the top , this mongrel was in 4th and doing 50kmh plus and still pulling at the top w. t. f. , if I had left it in 3rd the bugger would have been flying at the top !! Now the worst part of this exercise I have refitted his old diesel into the donor van so we can sell it off and get some money back should finish tommorow . Any one wants any info please feel free to ask . Howard

[Sunny43.5]

Just a follow up I am not a mechanic I have been in the motor industry as a motor trimmer for 30 years and for the last ten years fitting sunroofs , I did spend a lot of time as a kid helping my father when ever he had to fix the famiily cars so I just picked up the basics of car workings . I you want to know my most bizzare mechanical feat back in the 70,s I had a 4 cyl 1.6 litre Toyota Hi ace van the engine in that was absolute crapped so what did I do , no not rebuild it I actualy transplanted a Holden 186 6 cyl engine and auto tranny into the van fitted the diff and shortened the tail shaft made my own exhaust ,. The van went like a bloody rocket but was a mongrel to keep the temp correct because of where the radiator was in a Hi Ace ended up with thermo fans and a second radiator to help . Howard

[Jmac]

Good job Howard, good to see you had a stab a the belt. I got injured lately so was sort of relieved when you messaged me, anyway im vertical again for the win. Anyway dpont be surprised at the strength ofthe 2.5, im pulling all my gear in mines with over 320k on the clock and is still like an ox. Service it regular and itll be good. My horse goes everywhere and best of all its still comfy to drive. Great vans mate
Cheers
Jmac

[Sunny43.5]

Thanks Jim good to hear your back on your feet maybe I should think about becoming a mechanic NOT BLOODY LIKELY I will be glad to have clean hands again and not spending my weekends laying on cold tiles with grease and other **** getting in my hair , not to mention skinned knuckles etc LOL Howard .