Ok, surgery time, but a question or two first.

[Silver Talon]

Ok, so this coming sunday, the 18th, im having a garage bbq, and having a friend come over to yank the motor out of my merkur. I know i need the whole motor (duh!) all the wires (how hard is that, much involved? and is the computer inside the car, like passenger footwell or something?). What else do I need to pull out of the merkur??? My Ranger is allready electric fan run, so i can leave that in the merkur. Radiator? the stock ranger 2.3 looks bigger than the merkur one, so that looks fine. I cant think of much else.

My biggest question is the clutch and tranny for the ranger. Its a stock 91 ranger tranny (5 spd), with a new stock clutch in it. The rear end was swaped to a 3.73 limited slip from a newer splash ranger too. Will my stock clutch and tranny bolt right up and work with the merkur engine and flywheel? The merkur is a 5spd also, but alot diff from the ranger one. Do i need a new flywheel or clutch for it to work? I would much rather just bolt and go, but I figured it wouldnt be that easy. I know the stock tranny isint the strongest in the world, and I will beat on it, but no big clutch drops or anything (well, mabye a few ). The big day is getting closer, and I just want to make sure im prepaired.

Any advise from anyone that has swapped motors with a donor car?? I wont have the car running in the same day im sure, but would like the merk motor atleast bolted into the ranger, but the end of sunday.

Any help is greatly apreciated!! I cant wait!!

P.S. Yes, ill try and take pics too!!

 

[scotts90ranger]

if the clutch has been in your truck for a while, get a new clutch, if it's fairly fresh use it... the stock ranger tranny will be fine. it's pretty much a bolt in affair, if you have A/C you'll either have to ditch it or get a header, the one they sell at turborangerforums apparently works well.

use the stock ranger wiring harness and add the wires for the boost controller and vane air flow sensor and intake air charge sensor if applicable.

and a tip, if you are planning to use the stock turbo manifold at all, get yourself an oxygen sensor plug and a bung to relocate it.

 

[Silver Talon]

Clutch is brand new, so no problems there. Is there going to be a problem with the flywheel or anything???

I do have ac in the truck. But what is the problem, the ac pump itsself, or the heater box?

Im pretty sure I have to run the turbo computer, the ranger pcm wont work at 18lbs boost. Why you say to just add the wires?? Wont it be easier to use the whole wiring from the merkur, and splice what little needs to go to the truck dash and what not?

In the ranger, a stock ox sensor is in the wrong spot? I wanted to see about using the merk exhaust into the ranger, besides some bends down by the tail shaft, it should go in pretty easily right?

 

[scotts90ranger]

let's just say I had to notch my non A/C heater box for the exhaust even after moving the oxygen sensor... if you use the header you most likely won't have to do anything severe and be able to keep everything...

flywheel will bolt right up, crankshafts are the same pattern

yes, run the turbo computer, the connectors for the computers are the same. it's much easier to just add the wires to the truck harness instead of rerouting everything. I would also suggest swapping over to the DIS setup, if you look up at the FAQ I have some links that are useful, and I think I put how to modify the block to accept the crank sensor in there too... it can be done in a couple hours and I think it's worth it... replace the timing belt while you are there, along with swapping the ranger roller cam to the mercur engine, change the valve stem seals too (way easier when you are there) along with the rear and front seals.

in the ranger the oxygen sensor is mounted to the exhaust manifold, on the turbo engine it's mounted on the turbo outlet which puts it right in the middle of the heater ducting, I suggest moving it 6" down the pipe , and use the '91 sensor since it's what the harness is wired for, the turbo engine probably had a 1 wire sensor, the 4 wire sensor is better and should work fine, I'm running a 4 wire sensor on my '86 turbo engine and it seems to work fine. Although my O2 sensor moving suggestions only apply to the stock turbo exhaust manifold.

also, swap the N/A throttle body onto the turbo engine, it'll plug in easier, I wish I had done that...

 

[Silver Talon]

Ok, thanks for the help!

Do I just keep the merkur flywheel on the engine?? Or have to swap to the ranger one?

The dis setup is something for the future. I just rebuilt the igniton system in the merk, so ill leave that in for now. Timing belt is done allready, and the head got checked just a few months ago, as I had to do the headgasket in the merk, as it was blown. Front and rear seals have been done.

Whats involved in swapping the cam? Is it a straight swap, or more involved? I dont think its wise to tackle that before i get the swap done, and wired, and make sure it works in the ranger first. Swapping the cam in the truck shouldnt be a problem later right?

Ill have to look into the o2 sensor thing, not sure what i will be able to do at the moment. No welder at my house, and i dont even know how to weld anyway.

Anything else to watch for? I really apreciate the help!

 

[Silver talon84]

Thats why my pic isint there, im in the wrong account. This is the right one, lol. Cant wait to get this thing going!!

 

[scotts90ranger]

flywheels are all the same, only differences are the spline count on the friction plate...

on the ignition swap to the TFI on the DIS truck, I linked to a schematic to do that in the sticky...

cam is a direct swap, just swap all the ranger roller followers and cam in place of the flat tappet... can be done in the truck but you would probably have to pull the radiator and jack the engine up to get it to clear the core support

 

[mini274]

Trust me from one 91 to the other just re pin your harness for the ecm in the merkur its easier than you think... you need a non ac heater box to get this goin and have to notch the box 3 or 4 inches... 18 pound youll need a intercooler and injectors and a bigger mass air... so you can run stock boost and be ok but youll be pushing the injectors on 18 if you use the 39 pounders in the merkur motor... everything else is a bolt in process.. and it being a 91 you can use a 4.6 or 5.0 mass air i got mine off a thunder bird.. your running the ar 60 turbo i take it make sure and check the shaft play which should be good.... your down pipe will be fun you need to plug the O2 hole at the top and move it down 5 inches to put a new bung.. if you plan on runing more boost you will need a wide band to be safe but for stock its hot necessary.. the way your talkin your gonna run the 4 plug head just get a wiring diagram and you should be able to wire the distributor in... and good luck

 

[Silver talon84]

Ok, is there a writeup on the repinning the harness??

Man, the ac thing is killing me. I really wont use it much up here in maine, but for the month or so I would use it on or off, it would be really nice. Will I need a new heater box if I want to keep the ac or not? sounds like I would, and judging by the giant cone in the ranger engine bay, I would guess I would need one.

Well, On the boost thing. My Merk is running 18lbs, going by the prob not exactly accurate stock merkur gauge. It does have an aftermarket boost controler, but the stock wastegate on it. So its prob still at 15lbs from the factory.

Why do i Need a 5.0 mass air? Im a little lost on that.

The turbo is minty! I checked it when I pulled it out to do the head gasket.

The o2 is in the elbow now, so i should plug that spot, and just weld in a bung into my down pipe, or is it better to rotate it into my elbow on the left or right? Does it matter how close to the turbo it is? I would guess not, but making sure.

I havent got around to the swap yet, as a good friend's funeral last weekend, and then a cold this weekend, has cause me to put it off. So Im shooting for this coming sunday, to pull the merk motor out, and the ranger too. Ill have to wait on putting the merk into the ranger, as I have to figure out something for the 02 bung, and the heater box too. Thanks for all the help again!

 

[scotts90ranger]

if you get the header that they sell on turborangerforums then you should be able to keep the A/C, and probably the O2 sensor in the stock spot...

keep the VAM, no need to change that if it works

the boost controller is why the boost is high, the controller controls the wastegate...

as far as wiring, go to the sticky at the top of the page, there's several wiring diagrams linked in there. I HIGHLY suggest you take your time and don't rush, I did that and wish I had done several things differently, which is why I give certain pieces of advice. you can splice things and use the distributor, I have a link to things to do that I think, and there's diagrams of both distributor engines and DIS engines there too.

 

[Silver talon84]

Thanks for the info on the header, I emailed the guy that sells him, as his site says he is sold out. Hopefully not, but we will see.

The vam works fine, but it is the small vam, and plan on upgrading to the big vam, and hopefully a la3 after i get it running in the ranger.

Ill check out the stickies, and see if I have any questions. Im pretty good at wiring, and splicing stuff the right way. Been doing car stereos for 9 years now, and re-pinned a few things here and there, so as long as I can keep organized, I should be all set.

I want to try and take as many pics as I can, and make a big build thread about the swap, and re-pinning. That is if I can put down the wrenches long enough to take pics! lol.

Sounds like I have almost everything in order, anything else you guys can think of?

Thanks again!

 

[mini274]

you can also find the headers on ebay too... make sure and get the center mount... wat year merkur do you have as it might have an LA3 or something similar possibly better... just take your time and dont rush (as you probably know)

 

[Silver talon84]

86 merk. With the stock turbo. The ebay ones will allow me to keep the stock ac box, if they are the center mount? I dont want to get the wrong one, and would really like a straight bolt in swap.

Thanks!

 

[mini274]

the center mounts on ebay are the same ones jess sells on trf cause he sells em on ebay too... you just cant run a hx35 or 40 on em their not re-enforced like his are... the center mounts Should let you keep A/C... as it moves the turbo forward about 3 or 4 inches... if you gonna upgrade later its best to go ahead and get the center mount header as it allows for alot more turbo selections and everything else just goes easier.... be sure and check your numbers on your ecm and see wat they are i cant remember 86 but the 87 i got my motor out of was an LB2

 

[Silver talon84]

Ok, Do you know what turbo is on my merk? Its the stock one, but not sure what model it is. Ill check ebay if I dont hear from jess, or he dosent have any.