ok. Gotta make room in the garage for the electric Porsche and charging setup so the Montero has to get done. I'm getting some help from friends so here's where it's at:

The engine is in:









Everything fit together fine but here's what needs to be resolved:

1. The Ranger diesel starter won't fit because the Montero motor mount is blocking it so there's not enough room to install the starter. The motor mount/bracket will need to be modified

2. Decided to install a '89 Montero 3.0 V6 75 amp alternator on it so the connector is plug and play. Bracket is being fabricated

3. Decided to install the Montero 2.6 gas power steering pump on the motor with a fabricated bracket. Still not sure if I can get it to work with a remote reservoir.

4. I ordered a Ranger diesel accelerator cable from NAPA and it is nothing like the stock Ranger diesel cable. I will return it and get a generic Summit throttle cable kit and make it fit.

5. Need to sort out fuel shutoff solenoid connection and hook up the fuel system.

I hope to be cranking it within the next 2 weeks. We'll see.

- Pmontero

Number 3 - The 6 cylinder engine has a remote reservoir. The might work in place of the 4 cylinder pump.

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I'd be ordering the accessory bracket setup, and accessories from a UK pajero. Could prob get all those parts from UK Ebay breaker.

There are Canadian parts places as well, that specialize in JDMs. Rocky Mountain Imports in BC is one that I've used with good success...

Keep up the progress!

If you go the route of the 2.6 and fabbed bracket, pretty sure the StarQuest pump fits the same bracket. At least, I have a SQ pump on my turbo swapped, and I didn't do anything extra to mount it. The SQ pump has a remote reservoir.

Thanks for the info. If the guy who's helping me can't get the 2.6 pump to work, I know the V6 one will work if he bores out the shaft hole in the Ranger pulley and press fits it on the pump. (and fabricates a bracket) That will probably be the route we go so both the alternator and power steering pump will be from a stock V6 montero which is still readily available at most chain auto parts stores.

-pmontero

Well today was historic for the Montero. We finished all the fabrication, hooked up all the wiring and fuel lines and it fired right up!! These little diesel engines are amazing.

I did have one issue though. When it starts up it immediately revs to around 2500-3000rpm and stays there. The throttle on the injection pump is in the idle position. All I can think of is there is a cold engine startup on the injection pump that is stuck open? Any ideas from anyone? I'm so close to driving this thing now. Once this issue is resolved, it's time to go for a ride!!

fyi - if it helps, there are two vacuum lines that are coming off the injection pump that are just hanging loose right now. The only other thing I can think of is I have a fuel lift pump hooked up that is pumping at about 5psi. I don't think that should be an issue since the Ranger had one too.

Pmontero

Thanks to some dialog with another forum member, we're thinking that there is a fast idle lead that might be wired to 12v. We're going to pull off each of the extra leads we wired to see if we can isolate it.

Here's to hoping it's this simple!

Pmontero

Good luck! The only time mine idles that high is when I set the hand throttle too high on a cold start and go back inside the house. RRRrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr! Noisy when I exit the house again. My neighbors must love that. Not smoking as much on startup now since I did a 2000km trip in it last week though.

I took the day off today and worked on the Montero diesel fast idle issue. After a bunch of research and studying wiring diagrams, I determined that there wasn't a fast idle on the injection pump and something was gummed up and stuck in the pump. After running a large can of Liqui Moly Diesel Purge through the pump, I let it sit for a few minutes and then cranked it up. After about 30 seconds, something released and the idle dropped rapidly and the engine stalled. After cranking it again, it idled normally!!

I'm declaring victory today on the conversion since I was able to drive it down the street a few times. Here's the victory video. Enjoy!

Montero Diesel Conversion - First Drive

Pmontero

P.S. - I just checked the date on my first post on this thread and it was 2/20/07. I completed the conversion exactly 5 years to the date of when I started. LOL. I think I just set a record for the longest conversion! Slow and steady wins the race...

Let the build up begin!!!