Engine mount and 5spd differences V6 to 4cyl (Diesel swap)

[sweli]

So I am considering swapping a 4d55 or 4d56 into a LWB Montero. I do not currently own any of these vehicles or parts.

I know the TD will sit on the 2.6L gas motor mounts, and will bolt right up to the 5spd. Should be pretty easy swap.

Problem is that there are not a lot of LWB 4cyl 5spd Montero's out there in good shape for a decent price. There are more SWB 4cyl and LWB V6's available.

So the questions I have are:
1) Could a 4d55 be made to bolt to a V6 5spd? Difficulty?
2) Can a 5spd from a 4cyl model (do not know part #) bolt into an '89-91 V6 Montero? Difficulty? Which transfer case do you use? Drive shafts?
3) How different are the motor mounts between the V6 and 4cyl?
4) Assuming the earlier V6's use more ECU mess, is it that much more difficult to wire a 4d55 in place then in a 4cyl carb Montero?

thx

[sweli]

I could not figure out which type of attachements will post, so here is my swap list so far, put together from other forums.

Montero Diesel Conversion

The receiving Montero:
In the US, the Montero was first introduced as a SWB 2.6 in 1983. The SWB 2.6 Montero was last built in 1989. The SWB 3.0 was built in 1989-90 with very few 1990's imported into the US. The LWB Gen I 3.0 was imported from 1989-91 and switched to Gen 2 body style in 1992 model year.
Montero Diesel Conversion
What model years was the 2.6L gas engine and 5spd available in the Montero LWB Gen1?



Engine
1. Motor mounts directly. Are mounts steel with bushing, or rubber?
2. Bell housing: 2.6l gas engine uses same layout.
3. Flywheels on 2.6L gas and 2.3L TD are the same
4. Oil Pan: Need from 2.3 or 2.5L TD to clear axle. Could cut pan+/-1" from flange and reverse sump and weld.
5. Need Oil Pump pick up tube from 2.3 or 2.5L Pajero, or weld extension on yourself. POCUK.com has good UK wrecking yard contact section.
6. Change the timing belt and balancer shaft belt (and Idlers) immeadiately if you do not know the history.

Cooling System
1. Radiator: use stock 2.6L (gas) 3-row radiator.
2. Thermostat – can use what ever is in donor engine already. 170 works OK. DO NOT USE a thermostat hotter than 180 degrees! (even if NAPA says OE is 192-195)
3. 2.6l Gas has a mechanical fan, so does 2.3l diesel donor. Check mechanical fan clutch. Replace it at any signs of wear to prevent overheating.

Exhaust
1. Exhaust exits on same side of both motors.
2. Both exhaust systems are 1.75”. Should use 2.5" or larger for best results. Turbo provides enough back-pressure.

Glow Plugs
1. ‘Instant Start’ system is worth it if you can find one. Ford Rangers did get them. Get the relays and wiring harness from the donor truck.
Could make an instant start system with: Mitsu low 0.1-0.2 ohm glow plugs, a 1200 CCA battery and 200+ Amp relay.

Turbo
1. Ford Ranger Diesels: ’83-84 was NON-TURBO Mazda diesel, Larger turbo with waste gate on ’85-87
2. Cost to rebuild: $275 (seals, bearings, bead blast), $450 for cartridge from Turbo City
3. Intercoolers: Full kits available? Anyone have experience with inexpensive ones on Ebay? Volume calc or as big as fits?

Fuel system
1. Use a 12v inline push pump from a Ford Ranger 2.3 gas or diesel from 1986(+/-?).
2. 2.6l tank does not have a drain plug.
3. Filter with Water separator: Amsoil and Racor can be pricey. Goldenrod from Northern tools is $30 and filter elements are $4 (+/-).
4. Priming: 12v Push pump should do this OK. Some filter housings have a manual primer pump.
[Mitsu pickups had factory water seperators with little pumps on the side to bleed air out of line]
5. Injection pump service: Anyone recommendations? I have heard $400 and $800 for rebuilds.

Electrics
1. Battery: Some Mitsu Diesels use a single 95-115Ah. If using two, can mount a second tray behind one of the headlights.
2. Wiring
a. Forget trying to use the idiot lights, and go with a good set of aftermarket guages. Temp and oil pressure are the most critical. Mechanical vs. Electric?
b. Tach: Current Tach probably picks up from ignition system, and will not work with a diesel(?). Should be able to learn by sound of motor, when to shift. Aftermarkets avail.
C. 2.6l gas alternator and Ford Ranger both have Diode's and regulators built into the their alternators (?)

Power Steering"
1. New hoses needed to go from Mitsu or Ford (motorcraft) pump to rack?? Can be custom made. Cost?

AC
1. Will AC hoses from the 2.6L gas Montero mate to the compressor on the 2.3L TD? Prob Motorcraft system on Rangers. What about Mighty Max's or D50's?
I found local radiator shop that will make new hoses with custom ends, or they can splice into any hard line areas.
2. What electric signal activates the clutch on a 2.6L Montero compressor? On a Ford Ranger (Motorcraft) system?

[Bitsamissin]

Yes a 4D55 or 4D56 will bolt directly in where a 2.6 has been and the gearbox will also bolt straight up.
You can't do this on a V6 though the bellhousing is different and won't bolt up to any 4 cylinder petrol or diesel.
The V6 does have a removeable bellhousing but the KM145 (5sp) does not.
The only thing you can do is source a KM145 and bolt the V6 t/case up to it (virtually the same as the 2.6 t/case).

[sweli]

I am assuming the mounting points for a KM145 and v6 5spd are way different?
If you fab up new mounts for a KM145 in a V6 LWB, and bolt the transfer case back on, can you use the same drive shafts?

Are both clutches, cable or hydraulic?

Just trying to answer all these Q's, so that when the time arrives to start this project, and I cannot find a suitable LWB 4cyl, then I know there are other possibilities.

thx

[PHIL]

Just trying to answer all these Q's, so that when the time arrives to start this project, and I cannot find a suitable LWB 4cyl, then I know there are other possibilities.

thx

Just FYI, we didn't get the LWB 4banger over here...the first LWB we got was an 89, around the same time we got the SWB V6...