Help with a 2L-TE to 5L swap in a 96 LN112 Hilux

[BigNJpn]

Hopefully nearing the end of my Hilux engine journey. 2LTE is out and a shiny newish 5L engine is here and ready to be swapped. My diesel mechanic is a great guy, but not much experience with these JDM engines. He's been a great sport and agreed to do the swap but is hoping for clarity on these issues:

★Injection pump connectors are different

★There is a drain on side of oil pan on 5L

★Oil pressure sensor is different

★No egr on 5L

★Injectors are different

Grateful for any recommendations on how to explains solutions to these concerns to my mechanic and move forward and make the swap as easy as possible!

 

[BigNJpn]

Pump plug and pan

 

[Eurasiaoverland]

★Injection pump connectors are different

The terminal in the grey plug on the 5L IP with a green wire running to the rear solenoid on the pump gets a constant 12V when the starter switch is on 'IGN' and 'START'. The two blue wires are for the tachometer pickup.

★There is a drain on side of oil pan on 5L

That's obviously not a drain, how would oil drain out when the plug is above the oil level?
Just leave the plug in there.

★Oil pressure sensor is different

Use what came on the 2L-TE

★No egr on 5L

Great, what's the issue? Do you have the 5L intake?

★Injectors are different

Use the 5L injectors. The injectors should look the same externally (same size.shape.thread etc).

 

[BigNJpn]

The terminal in the grey plug on the 5L IP with a green wire running to the rear solenoid on the pump gets a constant 12V when the starter switch is on 'IGN' and 'START'. The two blue wires are for the tachometer pickup.


That's obviously not a drain, how would oil drain out when the plug is above the oil level?
Just leave the plug in there.


Use what came on the 2L-TE


Great, what's the issue? Do you have the 5L intake?


Use the 5L injectors. The injectors should look the same externally (same size.shape.thread etc).

I appreciate your non-nonsense reply! Very helpful for my overthinking mechanic. Any thoughts on how to connect the tach over from an engine that doesn't use an ECU?

 

[Eurasiaoverland]

I appreciate your non-nonsense reply! Very helpful for my overthinking mechanic. Any thoughts on how to connect the tach over from an engine that doesn't use an ECU?

That I don't know, Does the old pump have a similar tacho pickup? I'm afraid I have no knowledge of the implications of running a mechanically injected engine in an EFI/ECU vehicle with an auto transmission. Hopefully someone else can chime in.

 

[Tsvigo]

I appreciate your non-nonsense reply! Very helpful for my overthinking mechanic. Any thoughts on how to connect the tach over from an engine that doesn't use an ECU?

2 blue wire from pump is the tacho pickup. ur ori tacho will work but wont be showing accurate rpms as the ohms are different.

 

[BigNJpn]

The saga continues:
So I'm back to hopefully figure out why my 5L swap in to replace my 2L-TE isn't getting fuel. Fuel cut solenoid is wired up to ignition, engine wants to turn over but doesn't seem to be getting fuel. Pump has been primed, so open to any thoughts on what the issue might be.

Old ECU doesn't do anything to manage fuel, does it on an 96 LN112 Hilux?

 

[Eurasiaoverland]

Try putting 12V directly to the solenoid terminal from the battery positive. You only need a tiny wire. You should hear it click open. Keep the 12V on the solenoid when cranking and see if it fires.

If it fires up, you have an issue in your ignition or wiring. If it still does not fire up, crack the nuts on the hard lines going into the injectors and see if they are getting fuel. If no fuel, then the pump is most likely not getting fuel.

Have you seen the 5L running before?

 

[Tsvigo]

The saga continues:
So I'm back to hopefully figure out why my 5L swap in to replace my 2L-TE isn't getting fuel. Fuel cut solenoid is wired up to ignition, engine wants to turn over but doesn't seem to be getting fuel. Pump has been primed, so open to any thoughts on what the issue might be.

Old ECU doesn't do anything to manage fuel, does it on an 96 LN112 Hilux?

Mechanical pump, if your pump is rebuild. Make sure the solenoid is clicking. If it is second hand might no fuel because of the solenoid is broken.
Loosen and crank see if u see fuel in the fuel lines.