Diesel conversion (TD42 from TB42)

[Rossco]

Thought it was about time I should start a thread seeing as I have just plunged into doing a conversion on my GQ. Obiously the first step is to source a motor preferably off a donor vehicle so you can get the neccessary parts aswell. Fortunatly I managed to find one out of a rolled GQ which already had a Safari turbo and intercooler kit on it.

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The next step is to pull out the old motor and strip the engine bay which I am in the process of doing now. Next will be to get the fuel sorted, get rid of the gas and hook up the standard tank as well as the long range belly tank. . . Hopefully this weekend if all goes well. . . and bloody family social events don't get in the way - I know what i'd rather be doing!

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Anyways this thread is a work in progress so I'll post plenty more pics to come, and probably have a few queries along the way too!

[nissan-nut]

Hi quick question are the bellhousings the same for this converstion or do you have to change them ?

[Silver]

nice work, looking forward to following this project. 20 years ago a work colleague converted a petrol Tojo to diesel - obviously not a common rail or anything back then, but for some reason he replaced the fuel tank and fuel lines as he thought there was some issue with tanks and metal lines that had been used for Petrol. I now wish I had asked him why :-)

[AB]

Hi quick question are the bellhousings the same for this converstion or do you have to change them ?

Have to change them mate...

[AB]

Rossco just dropped the TD42 into his patrol today and It's all coming together.

Except for the last bolt on the engine mount wouldn't go in and a lot of swearing and cursing got him home.

He has taken a few photos of the progress so far but as always we keep forgetting to take happy snaps but I hope he can put up some great info once It's all done.

Can't wait to start this up and see it in action. Massive learning curve doing something like this and you really do learn a lot!

[big_fletch]

Good to hear its coming along nicley Rossco, Ill have to come have a look next time im down haha

[Rossco]

O.K., sorry for the lack of updates but I will get some more pics and info up soon. Unfortunately holidays and work have kind of been getting in the way of things a little! However it is starting to come together now, espacially now the new engine is in. Sorry for the late reply but the bell housing is different- just a standard td42 which bolts straight up to the gearbox. Stay tuned and I'll get some pics up soon.

[Rossco]

O.K. , many apologies agiain, but now the conversion is complete I figured I should finish the thread!

Unfortunately I didn't get any pics of the gas system removal (always the way when you get a bit exited!), however it is fairly straitforward as long as you make SURE the gas is turned off at the bottle and I also kept the filler assembly intact Also care is needed removing the tank as they are bloody heavy, especially if there is still gas in the tank, ideally try to empty the tank first. Once the tank is out it is just a case of removing all the lines, wiring and other parts like the converter.

Once the tank is out the new tank (I used a standard diesel tank) will bolt straight in, however the rear bolts are very tight beteen the tow bar (if you have one) and I just got away without removing it. I hooked up both the new tank and the old belly tank using a Pollak fuel swithing valve, however I haven't got it fully wired up and working as yet, so hopefully when it's working I will do a separate thread on the duel tanks.

Now it's simpy a case of stripping everything off the engine ready to be removed. This just takes time and plenty of zip-ties(and a few beers)!. I also labeled every wire that was disconnected to help with re-wiring with the new motor, which was very very helpfull.

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Engine ready to be removed.

Once the engine is ready to be taken out, it needs to be supported with the engine crane to remove the engine mounts, then lowered slightly to get to the top engine to bellhousing bolts as well as the botom bolts. Once they are removed it's ready to be prised apart from the bell housing and pulled forward and then out. Originally we tried to pull it out with the fan still on but found there was not enough clearance so it needs to come off.

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Removing the old motor.

Once the engine is out the bell housings can be eisily swapped over with the td42 bellhousing bolting straight up to the original gearbox! Too easy! Then the original clutch shift fork can be installed with new thrust bearing and it's worthwile putting on a new fork boot aswell and siliconing it at the same time. I found the old boot had been siliconed by me a while ago, however it had perished leaving a big split in it and allowing LOTS of water straight into the clutch resulting in the old clutch looking like something off the bottom of the ocean! Probalbly as a result of the last big Toolangi boghole I suspect.

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Old bellhousing to be swapped with td42 bellhousing

Now the new clutch can be installed onto the back of the new motor, however beforehand I decided to replace the rear main seal, seeing as it was apart and hopefully it won't have to be apart for a while to come. Once the rear main seal was replaced it was just a case of instaling the flywheel again making sure that the bolts are all correctly torqued. Then the clutch can be installed with a new spiggot bush, and it's ready to go in!

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New clutch on motor ready to go in.

For some reason (Can't remember why), I had to use the engine mounts off the old motor. They are slightly different and I think the diesel ones didn't clear something somewhere! Umm my memory must be fading, anyway, once that was done the engine slid in very eisily and everything lined up apart from the last hole as AB mentioned, however after looseng the mounts from the block it was enough to jiggle it in. Also before I put the engine in I gave everything a good coat of UltraCopper to keep everything nice and water tight.

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New motor finding it's new home

Now that the new motor is in the fun can begin, and not dissimialr to the removal, takes time, zip ties and more beer. The fuel filter assembly and vaccum resevior both mount in the same place as on a standard diesel GQ and already have the holes with captive nuts - too easy! However I lashed out and bought some genuine Nissan clips for the firewall for the fuel and vaccum lines at $11.00 each. A bit pricey for a plasitc clip but it makes it look original.

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Fuel filter and vaccum resevior and their lines

Mounting the intercooler was pretty straight forward once I figured out how it all went together. The brace that runs up and down below the bonnet catch needs to be removed, as well as the thermo fans, and I also had to move the can for the air-con. Once that was done the Safari Intercooler just has top and bottom brackes then a hole needs too be cut for the top hose. Also because I have a body lift the bottom hose was hitting the air-con pump, so I had to cut the bottom tube and use some rubber turbo ducting hose.

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Installing the IntercoolerP9030023.JPGP9030026.JPG

[Rossco]

Also the back of the grille has to be shaved down with a gringer to clear the intercooler, however I didn't get any photos. (Must of been getting exited again).

Once the intercooler was installed I was able to connect all the turbo pluming and airbox. Because I had to be different and locate my snorkel in a different place to everyone, I had to get the air box modified to rotate the inlet around to face the snorkel. Luckily however the hose just managed to squeze through, as you can see in the earlier photo. I also found that the hose between the airbox and turbo was hitting the dual battery tray (ARB), so I had to trim the corner to allow enough clearance.

Next was the wiring whch was pretty simple really, at least just to get it running anyway. The stater motor wiring is the same and hooks straight up, however the alternator is located on the other side so the wiring just needs to be extended which is pretty simple. Power on and off for the injector punp can be used from the fuel cut solenoid on the back of the carby which is the brown wire from memory and swithches with the ignition. All other wiring to the distirbutor, coil etc can just be cut and taped up being carefull to insulate all of the individual cut wires. Initially to get it going I just put the glow plug wire straight on the battery for 5ish seconds when it was cold which worked fine. I have now installed a momentary on type push swithch wired up to a glow plug relay. The only other thing needed to be wired up is the tacho which requires the diesel tacho gauge and has to be re wired form the gauge. Unfortuantly I'm not exactly sure how it's done as I am getting it done at Patrolapart.

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Glow plug relay.

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Glow plug switch

Finished product:
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Now all there is to do is get out and enjoy it! I have to say that I have no regrets whatsoever in doing this conversion and leaving unreliable old gas behind and enjoying a huge increace in power compared to the tb42 (especially on gas). You just gotta love that trusty sound of a diesel ticking away, especially a td42.

[AB]

Well done Rossco. I have seen this engine in action and it runs like a dream!

Can't wait to get it out in the bush mate!!!