1991 Ranger, 2.3 Mistubishi Turbo Diesel Swap

[gun_mike]

Hi Everybody,

This is my first build thread. I started out just looking for an 85-87 turbo diesel ranger. After 3 months of searching, one showed up on Craiglist. Unfortunately the truck was in terrible shape. Luckily it was a good price so I picked it up anyways. I pulled the motor and transmission out, a 2.3 Mitsubishi turbo diesel 4D55, and a Mitsubishi FM146 transmission with electronic Borg Warner Transfer case. I scrapped the rest of the truck aside from a a few other parts. I pulled the head of the motor and to my horror the cylinder walls and pistons and valves were in bad shape. There was long deep scratches in the walls, and big pits in the pistons, the head had a few dings in it as well. The motor ran when I got the truck, but it smoked white like no tomorrow. I attributed this to bad injectors or a problem with the injector pump. Looking back on it now, it seems like the poor condition of the bottom end was the culprit. Anyways, I decided the rebuild the motor. I sourced alot of japanese manufacture parts from online, new pistons, cylinder liners, rings, all the seals, waterpump, new connecting rod bearings and pins, and gaskets.
I was able to do most of the machining at my work (I am a machinist). I decked the head, and cylinder block. I installed new liners and had a local engine shop hone them to spec for me. I also rebuilt the cylinder head, new cam shaft, new upgraded roller rocker arms (from a 4D56). The valves seats were honed to match my newly ground valves. The old turbo was also shot, and I had a machinist friend who previously worked at a turbo manufacturing shop source me a new one with high quality Japanese journal bearings and coolant lines running to the cartridge (the one used in a 4D56). The motor is basically complete now, just need rear main seal housing and oil pan installed. Its also rocking a nice new paint job.

The truck this is going into is a 1991 regular cab 2.9l V6 4x4. It was a rebuilt truck with a nearly perfect body. I removed the bed and de-rusted the frame and painted it with chassis saver. The breaks have all been replaced, and new soft lines installed as well as a rear hardline. The interior has been ripped out and the slightly rust floor has been ground clean and is waiting some Tremclad paint. Over the next few months I will be swapping out the motors and getting this thing running. Here a bunch of pictures of my progress so far.

I will include more photos.

Regards,
Mike

 

[gun_mike]

Hi guys,
The motor is in and bolted up to the transmission. I had to take the crossmember extensions off the donor truck to bolt the motors mounts to. Glad I didnt throw them out! The mounts that came with the diesel engine ended up sitting about halfway on the crossmember. The engine fits perfectly in the bay with out any firewall cutting. I used braided stainless hose for a clutch line as the 91' slave cylinder and the mid 80s slave are different (12 o clock vs 3 o clock hose location on the bell housing). I also bolted up the exhaust, and intake manifold aswell as the turbo. Its looking pretty good. Heres a quick photo of the engine in the bay.

Regards,
Mike

 

[alwaysFlOoReD]

Looks good so far.

Sent from my XT1032 using Tapatalk

 

[Soledad]

That's a nice looking engine. Do you know about how much HP/TQ it will be producing?

 

[gun_mike]

That's a nice looking engine. Do you know about how much HP/TQ it will be producing?

Depending on where the engine came from, it will be any where from 86 to 92hp and about 130lb.ft of torque. With the addition of an intercooler, a boost controller for the wastegate, and a different blow off valve it should be able to break 100hp. Hopefully around 110 with about 150lb.ft of torque. The injector pump will have to be tuned by a specialist shop to achieve those numbers. I like the idea of adding an intercooler or charge cooler, its almost like free power!

Regards,
Mike

 

[Soledad]

When you get it running please post a video. I had a 2006 F350 6.0 for a few years and loved that thing. It was the cost of parts for performance upgrades that eventually lead me to get rid of it and get back into gassers. But that 6.0 ran flawlessly. And so I have a soft spot for unique diesel engines.

 

[gun_mike]

When you get it running please post a video. I had a 2006 F350 6.0 for a few years and loved that thing. It was the cost of parts for performance upgrades that eventually lead me to get rid of it and get back into gassers. But that 6.0 ran flawlessly. And so I have a soft spot for unique diesel engines.

I will definitely post a video of it when its running.

 

[gun_mike]

Update.

Well the truck is nearly complete. The engine runs and starts easily. The only things left to finish are, power steering pump lines, have a windshield installed, hook up the two regulator wires to the alternator, figure out why my windshield wiper motor doesn't work, and fix a camber issue on the front drivers side wheel.
Here's a short video of the truck running. Ill post photos when I have more time.

https://www.youtube.com/watch?v=lSYX1V3O4qA

Regards,
Mike

 

[1991fordranger1]

Nice job.

I'm trying to find a decent body for my swap still. Something about diesel Rangers that just make the world a better place.

I too am a machinist just curios did you do the head and block with a small cutter and back and forth? When I do heads or blocks i'be done fly cutters just curious is all. Turbo sounds great!

 

[gun_mike]

I though about using a fly cutter, but the mill I used to deck the head isn't the most rigid. I figured if I put less load on the cutter, the average surface flatness would be better. Was it really? I don't even know but it turned out alright. For the block I had to put it in the CNC because the knee mill table wouldn't go down far enough.

Mike