starting my diesel swap, 4cyl MB diesel engine into 89 Astro

[doyoulikeithere]

Hows it going Tinworm?
How has the beast been running ?

[tinworm]

Running great!

Haven't made any major improvements since my decision to swap motors next year, but I'm puttering around every work day reliably. Pending issues are I need to winterize the van a bit. No blower function, and holes into the cabin make for a drafty ride

EDIT-
Just realized I never mentioned the swap plan! Planning to drop in a 617 diesel with same gear ratios. Want to use this thing to tow cars around. Just too heavy a load for the 616 if I want to keep up with traffic

[LiftedAWDAstro]

What power/torque points are the 617 going to bring you to? Is it a sizable increase?

[tinworm]

Twice the hp and torque for one extra cylinder essentially. Plus a simplification of oiling. (I can go to a mb stock filter arrangement) Don't know torque numbers off hand but the 616 is about 72hp, and the 617 is around 130-140hp, with corresponding increases in torque as well.

With the same gear ratios, probably tow anything. I recently pulled an excellent motor out of a parts vehicle

[doyoulikeithere]

Wow those are some way bigger numbers for just 1 more hole.
so the oil filter will fit a bunch better, but, it will be a fair bit longer.
Will you be moving your shifter location back a bit or is there still room at the front ?
should be a towing beast when your done !

[tinworm]

Im going to compensate forward. Preliminary measurements looks like the engine will fit with the tranny in the same place. Should even fit with the radiator, i will have to go with an electric fan though.

One question area is the brake booster area/power steering pump area. New motor mounts have to be made, but honestly everything else should be plug and play hopefully

Right now im calling it a long weekend swap. we will see when it actually happens

[mdmead]

Right now im calling it a long weekend swap. we will see when it actually happens

Yeah, I started one of those once. I've already had to move the pieces from Dad's shop to my own. I'll finish it one of these days!

[doyoulikeithere]

Yeah, I started one of those once.

once upon a time in a land far far away... Lol

Thanks Matt,
I was having a bad morning but that gave me a good chuckle !!


Anyways, Im wondering if it is the large vacuum booster thing thats in your way TW ? , because I have often contemplated upgrading to the hydro-boost brake system from a newer van like one of my 1990's has (the AWD, not the GT). The hydro-boost system uses up less area in the firewall area, and might give you better brakes plus the clearance you need to fit what you wanna fit. Just a thought, might not even help, but thought I would toss it in the ring there....

[tinworm]

still dealing with the startup issue after shutdown.

I did change from the overboost valve to a giant fuel selector valve you can actually feel activating when you turn the key. There is no question its fully turning, and the way the vehicle operates is the same.

There is no reason this arrangement should not work properly, with the key on, the vac to injection pump is fully open to atmosphere, yet im still having issues starting back up right after running. Ive tested the line, and no residual vac in the line, yet still the hard to restart

Im wondering if maybe my issue is the injection pump shutoff valve itself. Im researching if maybe its sticking or something of that nature that would prevent the injection pump returning to the start position.
It really acts like the line is still seeing engine vac, but its not at all. Instant bleed off. This is a weird issue

Here is the change in vac shutoff valves-

first version-



version 2 over the top solution-

[doyoulikeithere]

Hi Tinworm.
Just spotted this guy putting the same engine into his toyota 4x4.
Thought you might be interested...
http://bb.bc4x4.com/showthread.php?1932 ... ost1211178

[tinworm]

Hi Tinworm.
Just spotted this guy putting the same engine into his toyota 4x4.
Thought you might be interested...
http://bb.bc4x4.com/showthread.php?1932 ... ost1211178

cool, Thanks!

[tinworm]

alternator bearing is failing, so parked the van waiting for a new one and starting checking things over. Finally realized why im having so much trouble with my turning radius and cooking tires.

The issue comes from me going with an aftermarket lower control arm, aftermarket drop spindles, and an aftermarket new front swaybar.

Until now if you cut the steering wheel all the way over, the tire would hit the swaybar and stop the van, depending on how hard you tried to turn. In tight quarters it was really a problem. Now I realize why I was having this problem.

The aftermarket drop spindle has a bolt hole and I neglected to install a bolt and adjust where my wheel stop should be. whoops



cooking tire-




good news is that with this knowledge, I can get larger tires and install a wheel stop for them. A little beefier rubber would look good

[tinworm]

it is time. 617 swap commencing.

I have the day off today, waiting on materials for work, so lets see how far I can get on this swap today. Intended repower plant is a 617 out of an 83 300D

[tinworm]

I want to take a moment to rant about the passenger GM motor mounts on these vans. Who in the holy hell came up with that design??? What in the hell were they thinking making it a bolt at the end of a huge extension with a 15mm swivel on the very tip? What the !@#$ kind of idea is that

!@#$%, its messing up my new motor support arm fabrication plans on that side, going to have to leave the old mount in and change it after the fact. Impossible to change in the position I have it now, on the ground with the motor jigged up

Ok, back to work, I feel better now

[doyoulikeithere]

I want to take a moment to rant about the passenger GM motor mounts on these vans. Who in the holy hell came up with that design??? What in the hell were they thinking making it a bolt at the end of a huge extension with a 15mm swivel on the very tip? What the !@#$ kind of idea is that

!@#$%, its messing up my new motor support arm fabrication plans on that side, going to have to leave the old mount in and change it after the fact. Impossible to change in the position I have it now, on the ground with the motor jigged up

Ok, back to work, I feel better now