Has anyone ever swapped a idi turbo diesel to a powerstroke? If so, please help!

I wouldn't have a guess why. the 99 and up is a much better engine in my opinion,

I'm in the process of putting a 96 powerstroke in a 94 chassis.

That isn't an option for me. Powerstroke is to me anyway a 99 and up. Anything around here that's older is either in the smelter or a scrap yard. Electronic injection is the way to go anyway

What's the difference between 94.5 to 97 powerstroke and 99 and up??? I'm a complete loss on this one.

The earlier diesels use a mechanical injection pump with individual fuel lines going to each cylinder run off a gear drive from the crank. Modern diesels the computer monitors the engines fuel burn and one high pressure pump pressurizes the fuel and electric solenoids let the fuel shoot in the cylinder at the precise time, in the late Powerstroke 7.3 it will do that 2 shots per firing cycle (quieter running and much more complete fuel burn), the 6.4 for instance I believe it shoots 5 times per cycle.

To take out a 7.3 and remove all the electronics and then put all the mechanical stuff to make it work for a poorer running engine, I'm at a loss as to why someone would do all tha, but hey, whatever blows your dress up!

94.5 to 97 powerstroke engine is the same engine as the 99 to 03 powerstroke, they both use heui injection, the 7.3 idi share nothing at all with a 7.3 powerstroke, and for a power standpoint in a 7.3 the single shot injectors make more power when you go with bigger aftermarket injectors. My post was really sarcasm, the 94.5 to 97 powerstroke uses a mechanical lift pump but are not mechanical injection. I think you need to do some more research on the difference between the 94.5 to97 and the 99 to 03, as you can swap them around as long as the 94.5 to 97 truck has e fuel as the 99 to 03 has no eccentric on the cam for a fuel pump.

You do realize that the 94.5-97 7.3 and the 99-03 7.3 are the same engine and use the same type of electronic HEUI injection system right? The only difference is the older ones have a engine driven mechanical fuel pump, no intercooler ,smaller injectors, and a different turbo, but all of those parts can interchange between the two. Also the 2 shots per cylinder you are referring to is for the 99-03 models that use split shot injectors, they where only used to make the engine quieter and for better emissions, they are not more efficient than a single shot injector is.

Swapping a 7.3 Powerstroke into an older 94 IDI truck would be possible, and the best way to do it would be to get a 94.5-97 truck to use as a donor then swap the engine, whole wiring harness and possibly the dash and gauges to make everything work. If it was me I would swap a 94-98 12V Cummins in it, they are all mechanical and require only 2 wires to make it run, and they can make more power for cheaper and get better fuel mileage than a 7.3.

So what the original poster is doing is putting a 96 powerstroke engine where his idi is. You can't put any idi parts in a powerstroke.

That's correct.