Hi all, I have just converted a 2004 Navara to a TD25TI from a 99 D22. I had bought the 99 D22 dirt cheap as a fixer but it was too far gone. So, bought the 04 Nav with no engine and set about fitting the TD25.
I used the complete engine and gearbox as the bell housing on the Nav box is different but the rest of the gear and transfer boxes are identical. As expected, the engine and gearbox mounts lined up perfectly as both trucks were D22.
The standard exhaust downpipe fron the 99 fitted directly onto the 04 system.
I used the 99 radiator as the top hose on the 04 rad was at the wrong end.
The coolant temp sensor on the TD25 works perfectly with the 04 guage,the wire for this and the charge warning light just had to be extended to reach.
The glow plug system was a bit of a headache so I retrofitted a common glow relay and ran a pre wired LED from this up into the original glow light cavity in the instrument cluster.
The TD25 injector pump has the NATS immobiliser box on the shutoff solenoid, I simply smashed it off and ran an ignition live to the standard solenoid which sits enclosed within said box. The other solenoid on the pump doesn't appear to be needed and can be left alone.
I used the power steering pump and pipes from the TD25 as the 04 ones were different, but I retained the original 04 plastic reservoir, the feed pipe from this to the pump is a good fit. One of the metal steering pipes was slightly different and a 90 bend had to be straightened out to allow it to fit onto the steering box properly.
The TD25 EGR and the throttle butterfly were controlled by an ECU on the 99 truck, I have just blanked the EGR pipe and removed the disc from the throttle, this has not had any effect on performance.
The only thing I have to sort out now is the tacho, but I have a couple of ideas up my sleeve which I will try, and post the results.
The truck has been on the road for about 3 weeks now and seems to be fine....touch wood!
artycheer: .
