I've owned this L300 for about 2 years now. During that time i've gone through 2 headgaskets on the old motor. Not too sure what the cause of the overheating was, but I'm suspecting it was the radiator. Needs a good back flush.
Being fed up with repairing that motor I purchased a 4G63 out of a L200 from Chch; was told it was in running order, after driving all the way down to Christchurch to pick up the motor it appeared to be a crock of shit. The motor was missing the balance shaft belts, the water pump had snapped fan studs and there was no cam tensioner.
Anyway after driving from Nelson to Chch I was not going to leave without the motor, so I offered the seller half the price he originally sold it to me for on Trademe and I drove back with a Peice of shit 4G63 for $55.
The motor sat around in the yard here at work for half a year and then I finally got to work and started working on it.
I purchased a engine stand and crane from Ripco for $399 during their fathers day special, was too cheap not to.
After stripping down the engine I checked all the bearings with plastigauge, they were all within spec so I chucked them back in. Also checked a few other things like crank end float while I was at it. I put the block in the Turbowash at work while it was stripped down and it looked spanking new after the clean.
I had to grab quite a few parts (tensioners, oil pickup and things like that) from the 4G63 that used to be in the L300 as I didn't like the looks of bits from the L200 engine.
I installed the oil pickup, used the sump from the L300 engine as the L200 one varied in shape a wee bit. Installed the tensioners.
Had the head from the L200 engine crack tested and checked for straightness and it was mint. Didn't do anything else to it but now I wish i had changed the valve stem seals. Fitted the head to the block and continued.
Reused the water pump from the L300 engine as it was only about 2000km old and looked to be in great condition.
Used the pulleys from the L300 engine seeing as the L200 didn't have powersteering. Turned out the L200 4G63 didn't have a required spacer on the crank pulley that is required for the powersteering; didn't find this out until I went to fit the powersteering pump and the pulleys were on the piss with belt allignement, anyway got that sorted and Got the belts all installed (balance shaft, cambelt, powersteer and alternator belts).
Everything was all installed on the engine apart from the manifolds, I chose to leave these off as I could see it being a hassle with lowering the engine in and getting it mounted up. But I did decide to install the gearbox while the engine was out, as It appeared to be a bitch to get the gbox on while the motor was in the car.
Used the flywheel, clutch and pressure plate from the L300 engine as it was in a lot better condition. I cleaned up the flywheel with emry paper and blasted it with brakecleen (also used this on the clutch). The clutch was in such good condition that the springs still had the blue paint on them. I made a clutch allinging tool as I didn't want to fork out for one at the time as funds were tight. The tool worked great. So had the clutch and gearbox installed in no time.
Then it was time for the installation, had to stuff around a bit with chains on the crane to get it short enough to clear the roof of the van, sussed it out eventually.
Removed passenger door, wheel and seat and got the bitch it. Was bloody awkward as the weight of the gearbox unbalanced things a fair bit. Had to remove the top mount from the gearbox to get clearance with the firewall and put a trolley jack under the gearbox to lift it up from the ground. Once she was in I had a cunt of a time alligning the engine mounts, but once again managed to get it sussed.
So tightened up mounts accordingly, reinstalled driveshaft and fit gearbox mount back to box. Plumbed up the power steering lines and plugged in all wires that I could at the time. Refitted exhaust manifold. Things are looking pretty good. I've compiled a list of things remaining which can be viewed below. I hope to get all these things completed after work tonight!! And with fingers cross she will run.
1. Put battery on charge. [charging now]
2. Flush radiator [complete]
3. Bolt exhaust manifold to down pipe flange. [complete]
4. Tighten Driveshaft to Diff bolts. [complete]
5. Find suitable nut for bolt to mount starter motor & mount/wire up. [complete]
6. Secure shifter cable bracket. [complete]
7. Secure clutch cable bracket. [complete]
8. Tighten gearbox upper mount. [complete]
9. Repair reverse sensor switch.
10. Repair earth cable on top of gearbox.
11. Fit thermostat with gasket to inlet manifold [complete]
12. Fit inlet manifold with new gasket. [complete]
13. Fit all vacuum, fuel and coolant hoses to their appropriate locations. [complete]
14. Fit distributor. [complete]
15. Fit coil & ballast. [complete]
16. Wire up distributor, coil and ballast appropriately. [complete]
17. Fit new spark plugs. [complete]
18. Connect distributor cap and HT leads to spark plugs in appropriate order. [complete]
19. Fit oil filter. [complete]
20. Ensure sump drain bung is tightened. [complete]
21. Pour in new engine oil. [complete]
22. Pour in new gearbox oil. [complete]
23. Top up power steering. [complete]
24. Fit radiator & hoses as well as fan shroud. [complete]
25. Pour in coolant. [complete]
26. Fit air cleaner assembly. [complete]
27. Ensure all hoses clamps are secured [complete]
28. Fit charged battery [complete]
29. RUN ENGINE! [complete]
30. Check for leaks etc. [complete, leaking mildly from metal water to heater hose]
31. If all ok, which it will be. Bolt seats back in. Clear path behind and remove vehicle from container. [complete, apart from drivers seat]
