A little more progress and research today. I learned that a cordless sawzall with a torch blade is a fabricator's best friend!



I cut the exhaust manifold off below where the pipe splits. I need to remove the catalytic converter so I'm hoping to get a pipe bent and welded from the rear cat converter mount to the exhaust manifold on the 4D55 motor. (still mounted on it)

A little more research on the radiator neck. The Ranger had the highest point of the cooling system on the engine at the neck.


While the diesel Montero will have a more traditional high point on the stock Montero radiator. Here is the neck I sourced from a Mighty Max 4D55 that I will use if the engine mounts with the radiator at the high point. If the engine sits up too high, I'll keep the Ranger neck.



Now to the alternator wiring. The Ranger alternator has two connectors. One with two brown heavy gauge wires and one white wire.



And another with a green, yellow and white wire.



Here are the Montero alternator connectors. The first connector has a white wire with red stripes and a blue wire with red stripes. The second connector is just one heavy gauge white wire.



Dylan, if you see this post, I need some help on how you spliced the Ranger alternator connectors into the Montero alternator harness.

Here is a final shot of the engine mounts removed from the Montero 2.6 gas engine that appear to be a perfect fit for pre-tapped holes on the 4D55 diesel motor. I haven't removed the Ranger mounts from the motor yet so I haven't test fit them.



This afternoon I'm going to finish removing the rest of the AC system and get the motor positioned so I can start removing the oil pan.

More to come.

-Pmontero