Hi guys Ive had a 1985 l300 4x4 van for a while now when I first bought it it had the 2.6 conversion done came with receits for engine rebuild about 20000k before I purchased was also set up with dual fuel. I will try & keep this short after about 50000k the motor spun a big end bearing not having time to rebuild the motor I managed to lay my hands on a 2.6 litre manual TR Magna fuel injected very cheap. So out came the motors the original sump was badly cracked around the mounting surface so I left the magna sump on a little modifaction with the BIG ADJUSTING TOOL (hammer) so it cleared the front diff pumpkin wasn't quite enough room in engine bay for fuel injection without modification so I fitted inlet maifold & carby from a TP Magna made the lpg easier to hook up had to run longer radiator hoses the magna water pump is at the rear of the motor now that it runs north south the original flywheel clutch & bellhousing were used. A few months ago I thought I would do something with the dreaded rust around back window found it was worse than it looked so I started looking for a complete rear door found a few but most had same problem. Kept searching usual places then found a complete van on ebay with original 2 litre & original 14 inch tyres no rust tinted windows & immaculate interior. Motor had overheated the owner had been told it needed a new head decided he didn't want to spend any more dollars on it (had a recent gearbox rebuild & new clutch) I parted with my hard earned thought Owell just pull the head off have a look see should make a great van. How wrong was I block has a 2 inch hole in it. NOW FOR DECISION TIME do I replace the motor with a standard 2 litre or go down the 2.6 litre path my questions are
How well do the vans go with a 2 litre when fitted with 15 inch tyres
If I fit a 2.6 from a sigma does the 2 litre sump & pickup fit
Will the bellhousing from the 2 litre bolt straight up to the 2.6
I know there is some older posts on this forum on fitting the 2.6 but I couldn't really find the answers any suggestions greatly appreciated
Brandy

Hi Brandy.
Sounds like you have had some dramas!
Lets start at the basics:::: You have fitted a 2.6 from a magna so that proves you have the larger diameter fly wheel and clutch and bell housing. Please double check whether it is a big bellhousing box.....Any 2.6 Pagero mtr will fit staight in with NO mods including sump (assuming your sticking it in your 4x4 van)
Use the rear door off the 2wd van on your 4wd van as that is a straight change over (other than demister and possibly rear wiper/washer. The wires are there but the order in the plug has to be changed) Its a huge job to change a 2wd body over to a 4wd one.(although it can be done!)
A 2.6 sigma Auto(Narrow block) will bolt up to Early bellhousings but the sump and pick up are wrong (must change for Modified Pagero sump and pick up Easily obtained! Also 2.6 sigmas are getting old now!
A magna mtr can be changed to front mounted water pump with the use of earlier timing cover BUT this must be modified for hydraulic balancer tensioner (Web across lower edge) Later Magna carby manifolds and heads have LARGER Water transfer passages so watch out for that IE: earlier carb manifolds will fit but need blanking plates welded onto manifold to mate with head to avoid major leaks! Read My earlier post 2.6 into l300 for more details HOWEVER that covered late engine into early 1.8 Would seem as though yours wont require that sort of work

Please feel free to e-mail me at custombikes@bigpond.com to clarify any points or queries
Regards Ken

Further notes to the above post:

A point to watch with any late Magna engine is OIL PRESSURE at a HOT idle

The late Magna engines run a "Bleed" type lube circut to the balancer chain thus diminishing the supply to the balance shafts and hence the big ends. example: the balance shaft rear bearing wears and a loss of oil pressure to the big ends (and Mains) is the result Beware of all second hand engines Typical sign of wear is a good period of time before a cold engine raises oil pressure at first start (sometimes a minute or more!)

There is a modification to eliminate the balance shafts but the resultant engine vibrations make the l300 body vibrate something awful, so much so , that when I put a balance shaft mtr back into my van It literally turned from a noisey dog into something reasonably pleasant to drive!

Hi guys
Thanks Ken for the info, in trying to keep the post short I left out some info both vans are the 4x4 type. I dont want to have both vans off the road at the same time so I guess my best option would be to fit a pajero motor to the van with the original 2 litre like you said the sigma engines are getting pretty old now. Will I use the pajero flywheel & clutch or the original 2 litre.
Ken I will definatley send you a email soon to clarify a few things.
many thanks brandy

Hi all
Just a short update I am going down the 2.6 litre path managed to find a complete sigma with auto very rusted body motor has good compression runs well Just a matter of chasing a few more bits & we are away picked up a pajero 2.6 litre sump & oil pickup for $15 now it is a matter of finding time. hope to add some picks soon
Brandy

Hey guys
Had a good weekend achieved a bit got the motor out of the sigma got rid of the bits I don't want PROBLEM! I lent my workshop manual can't remember to who. Anyway can someone help with flywheel bolt tension & clutch bolt tension
thanks
brandy

I use a Pajero NA-NG Manual for all running gear and torque settings Flywheel 137Nm Clutch 21 Nm don't forget to use Loctite

I have had my 2.6 Scorpion in for nearly 500.000km with one blown head gasket which was my fault for not using the genuine Mits cooling aditive combined with distilled water

I also got a Pajero power steering pump and braket and a three pully crank damper that put the P?s pump on the righthand side out of the way

Bolt the radiator on the other side of the existing brackets and you gain the 4inches you need at the front and used the Scorpion fan

While the rad is out consider geting the core replace with a heavy duty core

The worst part I found was modifying the gear rods to miss the exhaust

The end result is well woth the effort

This only works if you dont have aircon. I tried moving my air condensor forward but can only gain 20mm before it fouls on the body. Hence i havent done the 2.6 conversion yet.

It is possible, if you reply by email I will send you the photos

If you want any measurements please tell me and I will supply them

The Astron block comes in two sizes 310mm between the bell houseing dowls and 335mm

You need the 310mm if you want it to bolt up to your exiting gearbox.

As this block is used only on the automatic sigmas and scorpions you will need to use your existing flywheel

Do NOT be tempted to use the 2.0ltr clutch it will not handle the extra torque get a heavy duty cover plate and centre plate with shock springs this costs not much more than the std 2.0ltr

Make sure you get a gear reduction starter motor the 2.0lrt wont last long

While you have the flywheel off replace the spigot bearing using loctite and 3 light cenre punch crimps on each side so that it can only come out when you choose

If the engine mounts a not in good condition change them while th engine is out - its a lot less work

Hi Brandy

You say you have duel fuel, its something I would like to do

Where is you gas tank fitted? what size is it?

Thanks

Hi jgp
The gas tank is around 76litre but is about 60 litre useable it is mounted behind the third seat you lose a bit of cargo space. With the van I am working on at the momet I am looking at fitting the gas tank underneath but the original petrol tank will have to go.
Brandy

Hi jgp
I figured that it would be a good chance to replace the rubber mounts while everything was out located some engine mounts without a prob having trouble tracking down a gearbox mount though
Brandy

I just want to make one point clear not all pajero engines will bolt straight up!
mine is a freak....then...!
perhaps they might if you use the whole combination of gearbox and motor to transfer case.
I bought a pajero 2.6 and had to modify
adaptor plate wide block
engine mount's because of adaptor
clutch bearing=lengthen the thrust bearing and case harden. due to height issues from adaptor and clutch combo
1.8 clutch to suit 2.6ltr
radiator support brackets
wiring to the alternator
exhaust
power steering hoses.

sounded like a good idea at the time....ha ha ha it's been fun. ;)

cheers anthony :)