Pulling the Delica Engine … how?

Spent the day on wednesday trying to figure out how to pull the engine.  This is pretty technical … I am recording it more so that I have a plan on how to proceed with pulling the engine out of the van than with the expectation that anybody will read this … unless you’ve seized your engine …

Regardless, this is what I came up with after a lot of looking.  The pictures are not mine … I referenced the sites they came from at the bottom of the post … I listed them here more for a general idea of what needs to happen:

1. As components are being removed disconnect associated wiring.

  • tag wires with masking tape for re-attachment
  •  make sure wiring is tucked well back before moving engine

2. Remove items in engine compartment, including:

  • intercooler,
  • battery,
  • air filter,
  • wiper motor assembly (5 bolts) (remove windscreen mechanism from above engine … levers will unclip and leave a few bars ???)

3. Disassemble front of engine bay compartment.  This includes removing:

  • bullbar
  • bumper (mounting bolts behind park lights, remove lights to get at bolts?) (see 51-3 in Shop Manual)
  • AC fans and condenser (charge when re-assembled) (see 55-75)
  • grill (see 51-5)
  • 14-16 radiator + support panel (disconnect auto transmission pipes in front of radiator)
  • Panels
  • ???

4. Strip accessories off of engine (can leave some in bay?)

  • starter
  • alternator (16-11)
  • AC compressor (bleed air conditioning first) (55-62)
  • turbo (see 11a-9-1)
  • inlet manifold (see 11a-11-1)
  • steering pump
  • Note: ok to leave turbo and injector pump on engine
5. unbolt/disconnect gearbox in place.
  • support gearbox as close as possible to existing position (easier to line up when refitting engine).
  •  There is an access panel that allows you to undo the bolts that connect the drive plate to the torque converter
  • remove inspection cover on bell housing (engine side)
  • remove bolts holding flex plate to converter (crank engine over by hand to get at all of them)
  • Note: you do not have to drop the gearbox to reach the two top bell housing bolts, you will however need 2 x 500 extension bars or a combination of sizes to make up an extension bar of approx 800mm OR easiest removal is from rear by leaving drive shafts etc set up and dropping rear auto mounts, that drops engine down so they are accessible, once un-done remount rear gearbox up

5a. Or instead of 5 remove engine, gearbox and front transfer box (one long 7′ section – no gearbox bolts to undo or drive shaft re-alignment)

Pull engine out with a hoist

  • ??? pull engine straight out without lifting until it is free of the gearbox, makes it easier to put engine back in as all you have to do is align the engine onto the engine mounts (gives the correct angle).
  • definitely unbolt the torque converter first, makes life a whole lot simpler, + no need for a new seal + no loss of TXM fluid
  • When removing engine, be careful of a front diff sensor that the bell housing will fall/lower and rest on, put something in to protect the sensor

6. Possible problems to look for after engine is pulled.

  • seized pistons,
  • broken turbo shaft,
  • broken timing chain
7. On re-assembly
  • Install an EGR Blanking plate between the EGR And the manifold in place of the gasket


  1. http://www.mdocuk.co.uk/forums/viewtopic.php?t=20474&sid=c5d89213f0cd48266509f221e57ba5c8
  2. http://delicaclub.com/viewtopic.php?t=16250&start=0&postdays=0&postorder=asc&highlight=&sid=cb73f756889290c02bfff72626c5a050
  3. http://www.delicaclub.com/viewtopic.php?t=7650
  4. http://www.youtube.com/watch?v=-elVpkkaFGY


Delica Roadtrip; California or Bust?

I think the engine in the Delica van is seized.

Long story short did an oil change on the Delica a few days before we were to leave on our next planned road trip. Obviously was not paying attention … the gasket from the old filter did not come off with the filter … it stayed on the filter housing attached to the van. I did not realize this at the time … nor did the new filter feel any different when it was screwed on. I did not check the old filter for the gasket … I do not think I will be forgetting that check again.  As usual I idled the van in the shop prior to replacing the skid plates and nothing leaked.

 On tuesday Stephen and I left on our California road trip.  We were driving to Berkley, California so I could go to a workshop about the gasifier I am assembling, and then we were going to spend a few days visiting in the area.  We had converted the van so we could sleep in the back and we were carrying enough oil to get us there and about half of the way back.
At highway speeds the doubled gasket blew and the engine lost all of its oil within 5 kilometres of the house. I am guessing if I had reacted faster to the engine warning light (I had under a minute of warning; check engine light came on but nothing else … the engine temperature read fine) I would be better off right now. There was a bang from the engine (not good), some swearing from me (Stephen sat very still) and the van immediately lost power.

I got the van off the highway and investigated; oil everywhere on the undercarriage, and the coolant was boiling … really not good.  Once I figured out what had happened I re-sealed the oil filter (with just one o-ring), replaced the oil and tried to crank the engine (all on the side of the highway). It cranked briefly and then it seized … I tried the starter again and it just clicked. We were towed back to the house by North River Towing … not my proudest moment … looking back I wish I had a picture of it.  I still have not confirmed how badly damaged the engine is, but I am guessing minimally the engine needs to be pulled and worked on … if not replaced.

Still trying to deny that I just did this.

Does anybody know how to pull the engine on a Delica L400?

We Were Hacked!

It recently came to our attention that when you visited one of the pages of our website a number of completely unrelated popups would be launched in your web browser.

We did not do this intentionally, so we are guessing that somebody else added this feature to our site!

I believe I have fixed this problem, but if you notice anything could you post a reply to this post complaining …