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

[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.