If you plan on fitting larger tires at some point, a body lift might fit the bill. <img src="/forums/images/graemlins/wink.gif" alt="" />

Cool pics, I'm envious of the motor.

Yeah, I am planning to go larger but probably only 31's or 32's.... so a body lift isn't necessary for tire clearance but may be a good option anyway. I hadn't thought of that route.

nice pics - by the way, pulled my 4d55t from the 87 ranger diesel today. she's a bit gummed on the outside, but it was nice to see it come out without much fuss. THANKS TO PMONTERO and DYLANB for keeping such well detailed info on your moves - gives me alot of confidence and guidance on my swap - this is my first diesel... She was running great a couple weeks ago before I started dismantling, so I am looking forward to switching main bearings, timing and balance shaft belts, and serpentine, and then drop into my 1986 Monty. One question - can the Ranger diesel tank work on the Montero? I'd sooner pull the entire fuel system off the Ranger to ensure it works out right, but is it possible/necessary?

You could pull the tank from the ranger and put it in the montero, you'd just have to find a way to mount it. I find it easier to just use the Mitsubishi tank - it's already mounted and you have a fuel line into engine bay and a line to the tank from the charcoal canister that can be used ans the return line. Just add in an electric pump and you're good to go.

That's what I'd like to do, but I am concerned about running diesel through the fuel lines, and then what about venting... I am not yet sure whether the venting and routing of the fuel lines would be the same. Also, here's something I found STRANGE - when I removed the 4d55t from the diesel ranger yesterday, under the intake side, there was a fuel line that was leaking clear solvent like fluid - fuel, like gasoline?!?! [at least that is how it smelled]. what would this be from? could it be the water separator leaking what was in it? It certainly was not diesel, and this has only been run on diesel. I'm a diesel-rookie, so if this is typical, I hope a few of the readers get a laugh out of this. If I can empty the gas tank that's in the Monty, and drain the OEM fuel lines, I will certainly be further ahead than pulling the tank off the ranger, and swapping it in completely. I just don't want to send the ranger off to the wreckers if the tank is preferable by any means. If it's all the same, I'd certainly save the effort, and leave it with the scrapper. By the way - what pump should I use? ALSO - Someone mentioned they could source a full rebuild kit for the 4d55t - please PM me with pricing, I really don't want to have to order from AU. At least for starters I'd be needing timing and balance shaft belts, and a serpentine to boot, maybe some sweet alum. pulleys like seen in this thread...

Not really sure what you might have been leaking without seeing (or smelling it for that matter), but I think you'll be fine if the engine was running ok when pulled. As far as the fuel pump you use goes, any electric pump should work fine, mounted close to the tank. Doing a thorough overhaul on the engine while its out wouldn't be a bad idea, but if all you need is belts they can be bought at NAPA pretty easily.. I can get part numbers tomorrow.

cool - i think i could make out that the serpentine was a gates, but number wasn't visible. haven't gotten to the other belts yet - being xmas and all... will likely let the tank go then, with the rolling chassis of the ford - should I keep the wiring harness? apparently it's a good idea to keep the tach - but couldn't I just run a line off the alternator into the tach in the montero dash? that would seem easiest. also, the 'gas' smell was just old diesel - had a friend confirm that. Does anyone know if the clutch assembly/flywheel that is stock on the ford 2.3 diesel [4d55t] will bolt on to my mitsu 5 speed tranny? The ford was a 5 speed tranny... I was worrying about the starter, and am not sure about how to proceed on this - just bolt in? I'll likely check the splines on the ranger vs the splines on my parts raider to verify if they are the same, I hope they are, I want the diesel starter, as I hear it's the one I need to be able to turn over the engine. Merry Xmas to those who celebrate! Happy Holidays all!

You may want to keep the harness, I did just in case an am now wondering if it would have been easier just to use the Ford harness as I am having some wiring issues w/ the injector pump. You'll want to use the Ranger flywheel, and you can either find a good clutch shop that will come up with a pressure plate for what you need, or drill and tap the Ford flywheel for the Mitsu pressure plate like 89Diesel did. This will allow you to use the Ranger diesel starter.

Been doing a lot of parts scrounging and problem solving over the last few days. Kinda stuck on some wiring issues with the injector pump. 89Diesel, maybe you can share what you did. Apparently there is the fuel cut solenoid in there (which I know I have to wire to 12v switched power), but there is also an accel switch/enrichment solenoid type thing in there for the California trucks. Not sure if or how I need to wire that system, as the wiring diagram is pretty fuzzy and I don;t have all the components to that circuit anymore. I think I am going to hook it up to a switch and see if there is a big difference once I get the truck running.

Anyway, here's the concrete stuff I have accomplished lately.

Starter solenoid for glow plugs, mounted inside passenger fender.



Oil cooler and mounts, just in front of AC condenser and behind grille. Not finished quite yet.



I found the tach feed, apparently there is a revolution pick up in the injector pump that feeds it(White wire in the bundle that comes out of Injector pump). I pulled the Ranger tach and I'm integrating it into the Mitsubishi cluster, as I don't think hooking up to the stock tach will give me a correct readout.



I extended some of my power steering hoses which allowed me to relocate the reservoir to the passenger firewall and further away from exhaust heat.



Still got some wiring and stuff to do, more updates soon hopefully.

Great progress Dylan! You're definitely ahead of me. Two questions for you:

1. What did you do about the turbo oil drain line that went into the stock Ranger oilpan? I'm thinking of either drilling and putting a new fitting on the pan or cutting out the old one from the Ranger pan and welding it into the Montero oil pan.

2. I'm going to use the Ranger flywheel and I have a brand new Ranger diesel clutch. Do you think it will fit in the Montero or should I be looking for the Montero clutch instead?

My motor is sitting on the engine stand in the garage with the Montero for now. I need to do a bunch of seals, replace a broken timing cover and remove a pulley bolt that the head sheared off on the water pump.

Happy New Year,

Pmontero