Hi Folks,

Well, I'm back and soon to have a Montero SWB in the fleet again! As most of you know, I ended up getting heavily into biofuel research but I'm ready to get back on the trail.

I have a 1986 Ford Ranger diesel with the Mitsubishi 4d55T 2.3 turbo diesel engine and will be swapping it into a 1987 Mitsubishi Montero SWB 2.6 5 speed truck. I'm finishing the research and acquiring the parts for the swap and hope to have things complete for the summer offroading season in the NGA mountains! I'll put most of the information on doing the swap into this thread as it happens.

It's great to be back!

Pmontero

Oil Pan Differences

UPDATE: From a board member with a 1987 Mitsubishi Montero 5 speed with 4D55T diesel swap. The oil pan from the 2.6 gas motor will fit on the 4D55T and has a rear sump. The elongated oil pickup tube from the Ranger should work perfectly with this oil pan!

Here are two pictures of the '87 2.6 gas oil pan:





Notice in the second picture that there is an indentation in the side of the sump to allow it to clear the front diff. I believe this is why I would probably run into trouble using the Ranger pan even though it has a rear sump. (unless I dent it with a hammer)

My only concern now is whether the Ranger oil pickup will clear the lip around the sump in the pan.


From what I've found, the Ford Ranger 2wd diesel has a different oil pan from a 4wd Dodge D50 4x4 diesel pickup. It is my belief that the latter oil pan should be the correct pan to use for the Mitsubishi Montero and is most likely the stock oil pan for this truck where diesel is a factory option. Here are some pics illustrating the pan differences:

Ranger Oil Pan:



notice the orientation of the reservoir to the wider end of the pan. Also notice the elongated oil pickup to extend from the block connection to the other side of the oilpan where the reservoir is located.

Dodge D50 4x4 Diesel oil pan:



Notice the orientation of the reservoir to the wider end of the oil pan on the D50. I believe this oil pan was used on the 4x4 versions of this engine on the Ranger 4x4, D50 4x4, Mighty Max 4x4 and Pajero 4x4. I'm waiting on a picture of the oil pickup for the 4x4 oil pan but I'm assuming it is similar but with a short straight drop tube into the reservoir in the pan.

The difference in orientation of the oil pans was to allow the engine oil pan to fit with the front differential on a 4x4 truck.

Powell

Power Steering Pump Differences:

The Ford Ranger diesel and Dodge D50 diesel have two different power steering pump setups. The Dodge has the reservoir attached to the top of the pump and has a v-channel pulley similar to the power steering pump on a Gen I 3.0 V6 Montero.

See pump here:



Here is the Ranger power steering pump and brackets off of a Ford Ranger diesel. Notice the lack of an attached reservoir and the serpentine pulley. The reservoir is located remotely with a connector hose.



I need to decide whether to use the Ranger power steering pump and retrofit the high pressure hose and keep the Ranger serpentine belt or switch to the D50 pump and switch out all of the pulleys for the v-channel style. (psteering pump, alternator, tensioner pulley, vacuum pump pulley, crankshaft pulley, etc.)

I'm leaning toward keeping the serpentine belt right now so I can keep my new 80 amp alternator without having to retrofit a D50 v-pulley on it.

Pmontero

Miscellaneous differences:

I will need the radiator hose neck from a D50 since the Ranger has the cap mounted on the neck. (strange)

I plan to use the Montero radiator and have it rodded while it is out during the swap.

I will need to fabricate or located an appropriate brake booster vacuum hose for proper braking

I will use the air can from the D50 to accomodate snorkel connections through the quarter panel.

The starter and glow relays will be scavenged from the Ranger and set up on the Montero. Glow plug activation will be controlled manually from a button on the dash.

More to come!

Pmontero

I don't know where the vacuum for the brake comes from on the Ranger engine. Usually the diesels have either a vacuum pump fitted to the back of the alternator (eg 4d56T) or a separate vacuum pump (4m40 & 4m41).

If you intend using the alternator off a petrol engine, make sure you have an alternative source of vacuum.






This could be to make sure the cap is at the highest point of the hose/radiator?






I like that, but make sure about the voltage requirements of your glow plugs. It might be necessary to add a resistor to get the voltage down to the correct number.

The Ranger engine is the 4d55T and has a vacuum pump mounted just under the injection pump with a serpentine style pulley on it. The 80amp alternator is the correct alternator for the Ranger diesel just with a higher amp rating. I just need to make sure I can make or find a vacuum hose that will run from the vacuum pump to the brake booster.




Good point. That makes sense. I'll take that into consideration after the engine is mounted since I plan on using the Montero radiator. My thought is that the engine will sit down in the bay similar to the 2.6 petrol so I'll be able to use the cap on the Montero radiator. I'll keep the other cap/neck combo just in case. Thanks!




My engine is using the standard Mitsubishi green plastic top glow plugs that work with the 4d55T engine. (I think they are the same for the 4D56T too) Does anyone know what the voltage/ampreage requirements are for these plugs? The Ranger has a two 12 volt battery system. I haven't decided yet if I'm going to fabricate mounts for a dual battery system on the Montero. I'm considering putting in a "whopper powerful" single battery like my antique Mercedes diesel has.

Thanks for the comments. Any others with questions/advice/comments please chime in. I'll be adding to this thread as there are developments. The meat of the information will come once we start pulling the engine and retrofitting parts. I'll post lots of pictures!

Pmontero

I still owe you some pictures. <img src="/forums/images/graemlins/frown.gif" alt="" />

My 83 has a single battery. I'll get the specs from it.

Powell and Mark, GREAT to have you guys on here. Look forward to any and all input you guys provide over the coming months. Powell, if there's anything you want to compare to the 4D56, let me know. Pictures are easy to get, now that there's one in my driveway... <img src="/forums/images/graemlins/kewl.gif" alt="" />

Thanks Phil. I'll definitely take you up on that soon! Here is some more swap information from a board member who has successfully swapped a 4D55T into a 1987 Mitsubishi Montero SWB 2.6 5 speed:

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The motor (2.6 gas) started its life as the diesel. What this means is the 2.6 gas and the 2.3TD have identical mounting positions, as well they also have identical transmission bolt patterns. If you have the 2.6 gas motor from the Raider/Monty then use these mounts and engine brackets. I have a diesel Ranger now and they are different engine brackets. I looked at your oil pan pics and the diesel pan will not go in the Raider/Monty due to the sump issues. The 2.6 gas pan will however go in and you could use the Ranger oil pickup. I had to fab that part.

The aluminum bracket to support the p/s and vaccum pump on the Ranger diesels break mainly due to vibration. (after 300,000 anyhow).

Your point about the 80amp alternator is a good one as the D50 only puts out 35amps which isn't really enough. Pro and cons for the belts I think you should run what you have.

The glow plug system is very touchy. Push button will fry plugs I see it all the time. It is not that hard to incorporate your glow plug controller into the Raider/Monty The controller works well and then the plugs will last. Think about that. Mainly 8 seconds of battery voltage and they're done.
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Unfortunately, the glow plug controller in my Ranger diesel is fried and I have it wired to a push button. I may look into other ways to control how long the glow plugs are activated.

Pmontero

P.S. - MarkG, no worries about the pics. I found a breaker in Missouri with Ranger diesels and D50 4x4 diesels and a digital camera. They took the pics at the top of this post.

Great info - I'm hoping to start my swap in the next month or two as school starts to wind down. I'll post any info/ problems I come across as well.
If everything goes smooth we should get a wheeling trip together this summer.