uses a pulse timer for your glow plugs just wire it up to your ignition so when it gets power it will start a ten second count down(or what ever you set it to) then shut off.

Thanks LT. I need to figure out how to handle the conversion to a fuel return line to the tank. Any ideas on how to handle this? I'm wondering if the Gen I Pajero diesel uses the same tank with a different fuel pickup, level float and return assembly? I haven't looked at the 2.6 fuel assembly on the tank to see if this is one assemply that bolts to the tank? If so, I may try to source one from another country and replace it.

I think I'm going to pull the fuel tank anyway to have it boiled out so drilling and tapping for another tube for return is also possible.

Pmontero

when I did my swap I made a new bracket and bought a new ranger diesel tank from a gas tank warehouse. I also purchased a new sending unit for the tank. At the time all I had to work with was the Ranger system. I deep sixxed the OEM AC (we really don't have a need for it up here) and mounted the alternator higher, and put the AC compressor down low and plumbed it with a remote oiler and air filter so I had air. The only thing I had to do using the Ranger fuel system was lay new lines, I took all the other stuff right off the Ranger to simplify things. The mounting brackets I just raided from the breaker on an as needed basis. I think I used one from an Eagle, and one from the 2.6 minivan as it fit in the firewall nice and tight and was rust free.

Thanks for the detail! Here is another method from a private message from another member who's done the diesel swap:

On my 87 Raider there was a vent line (1/4" I think) that went from the engine compartment all the way to the tank. It was right beside the fuel supply line. This is used to vent the fuel tank thru the carbon canister. I checked that there were no restrictions in it and used that as the return. It works perfectly because the unused fuel amount is very little.

As for the brake booster and vacuum pump I have the original D50 alternator with vacuum pump on the back. I used some of the steel pipe off the D50 and some of the existing piping on the Raider. I got some small of hose from the wrecking yard to attach up the pipes. Now the pressure power steering hose did require fabrication. I used the factory D50 pump which was not far off the Raider 2.6 gas pump. The return line was not a problem but the supply was different size nut into the pump. I cut the pressure line pipe in the straight area then cut a 1" long piece of pipe to slip over the two and silver soldered them up. You could use a compression style fitting but I preferred the performance of the silver solder.

ok why would you need to change the tank out? why not use the stock gass tank?

Any comments on hooking up the throttle linkage from the '87 Montero gasser to the injection pump on the 4D55T? I'm also going to locate a manual throttle control to install on the dash to allow for warmups and for adjusting idle speed when running inverter and other electrics. The Ranger doesn't have this so I find myself holding the pedal when warming up.

Pmontero

any industrial parts store should have an aftermarket manual high idle cable. I have one and they work great.

Thanks. I'm going to check Mcmaster-Carr and a couple of local places to see if I can find a manual throttle.

I just ordered the airbox out of a Dodge D50 diesel. It looks like it should work well in the Montero with a flex hose going into the side of the truck for snorkel hookup.





With some cleanup, sanding and miracle paint, it should work out well. I should have the Montero swap candidate in hand by this weekend. I'll post some pics as soon as it's here.

Pmontero

I just ordered a spare flywheel from a Mitsu 4D55T out of a Ford Ranger diesel. The one in my truck I believe has some missing teeth as the starter does not engage sometimes. (I've tried two starters)





I will be installing a new clutch during the swap as well.

Pmontero

That ring is probably removable, and you OUGHT to be able to buy a replacement. Installation is easy.