Ranger Diesel Swap 2

Setting the Stage

I spent lots of "spare" time since the last update taking measurements in the engine compartments, making cardboard templates of things that stick out on the new engine and comparing them with the available space in the diesel Ranger (because I could measure them from similar points on the diesel engine that's already in it, otherwise the trucks are identical), seeing how things fit together, where the motor mounts to the frame, etc. All looking for anything that would dead-end the project, but didn't find anything.

I'll have to swap the oil pans between the old and new engines, as well as the intake manifold, both due to clearance issues. All of the accessories, alternator, vacuum pump and power steering pump will swap over as well. There may be some fabrication involved.

It's not necessary to start with, but I've been scoping out the possible location of one of the two intercoolers I have on hand. The grille area is already tight for space, I'll likely have to lose the fog lights in the grille on the new truck.

Also went back through my research from 16 years ago, dove deeper into the transmission and transfer case documentation, found a PDF shop manual for the new engine, and sorted through some of the spare parts that I bought back then to make the conversion (gaskets, mostly).

A friend visiting from Portland and I put the 8'x12' truck box I've had for a few months up on pier blocks and leveled it. This will be the disassembly and storage area for everything, so I don't clutter up my garage. Last trip over to the Big Smoke (big city), I went by Halbol Fleight* and picked up an engine stand and 20 gallon parts washer tank. I expect lots of grease, LOTS of it, from all three engines, and want to deal with it as painlessly as possible. Friend from PDX already loaned me a very capable engine hoist for the job. The truck box is outfitted with overhead lights, ample shelving, a roll-away tool cabinet that can be used as a small workbench, and there is a small assortment of tools, wrenches and sockets, etc, that might save me a trip back to the garage once in a while.

First step in this phase of the project was to make the red Ranger donor truck roll again. Last time I tried to move it, the front wheels were locked solid, and after dragging it around the yard with a 4x4 in an ineffective attempt to put it into position, I gave up and used the loader on my backhoe to pick the front end up off the ground and dollied it out of the way. This needed a remedy, as I have to be able to roll the truck into the carport where I will pull the engine out with the hoist, and there was no way I was going to be able to move it to that area with the tractor. The simple solution was to remove the front brake calipers and pull the brake pads. Full disclosure: a sledge hammer was involved, and it wasn't all that simple.

Really, things aren't going to get going until I get the old engine out of the donor truck and get the bell housing from it. Once I have that, I can install the starter on the new engine, shunt a few oil lines so it doesn't spew, and make it run. This is the necessary first step in doing the conversion. If I don't have a running replacement engine, then I don't tear down my white Ranger. If it runs, then I fab up some kind of radiator, fill it with water and run it up to temperature.

Until now, all I had for documentation of the installation of the diesel engine in the Ford Ranger was what little I could find in an old Clymer repair manual. Most of the information was vague, intended more for an owner who would be changing their own oil and such. No fuel system or wiring diagrams were presented, and I need both to do a proper installation of the diesel in my gas truck. On the off-chance that something more fully documented existed, I did a search on fleaBay* and found many instances of the OEM Ford shop repair manual for the 1987 Ranger. One listing included scans of the index pages, and it appears that diesel fuel systems and wiring diagrams are included, as well as very detailed procedures for servicing and disassembly of all parts of the truck. If tomorrow wasn't Columbus Day, I could go down the the Post Office and pick my copy up, it's been delivered, but won't fit in my P.O Box, so I get to wait until next trip to town this coming week.

This is a long term project, without a doubt. When I need a truck, I'm driving a Tundra that I borrowed. It has some issues, and I had to do a brake job on it before I could go anywhere. I put the first tank of gas in it last week, and I'm not used to that much sticker shock! There's a reason I drive the EV whenever I can...

*A FOOTNOTE: - I'm misspelling the names of these large, for-profit companies purposely because I find it amusing, but also because I don't see why I should be littering my website with their already well-known names. I do this with most every too-large institution, right down to the health care facility that provides my medical needs. Anyone want to argue about it on Facecrook? Look me up on Gooble.