New Project: Family Wagon! (part 3)

4) Preparation of Red

After wraping up the 1985 "freebie", the next step was to clean out all the parts and components in Red that would not be used for the conversion. All the smog components, ignition, brackets and other unnecessary parts were removed. The goal was to reduce the truck to the point where there is commonality with the diesel. In this swap, that means removing the gas specific inner fender panels and engine frame tabs. I used a plasma cutter to clean off the frame, following with a grinder to clean and prepare the frame surface for the diesel specific frame tabs.

5) Diesel Installation

I removed the diesel motor from the Canadian truck and prepared the motor with the parts from Spector Off Road. My plan for the install was to follow the method I had read on the IH8MUD.com forum. http://forum.ih8mud.com/ IH8MUD.com contributer Wayneraintree accomplished the motor frame tab installation in truck by installing the diesel motor with the frame tabs bolted to the motor. However, his method necessitated the removal of the motor for a second time to weld the frame tabs. I was encouraged by Walter to measure and pre-install the frame tabs to speed the process. This method worked out well and I would definitely suggest this to others, as there is an abundance of datum points for an exact installation.

With the motor in place and mounted, it was time to start installing all the pieces that connect the motor to the vehicle. This includes the intake, exhaust, starting and cooling systems. This process my starting at the fuel cap and working my way forward on the fuel system. Anything that was diesel specific was installed. Heat shields, brackets, everything was scrutinized for compatibility. I changed out the foot pedal and the special hand throttle cable special to diesels. I installed the inner fenders to obtain the brackets to support the air cleaner.

Overall, this swap was 99.99% nuts and bolts. I recall drilling only one hole to fit the diesel throttle linkage up high on the firewall. This was easily accomplished and there was even a access hatch plate next to the location, making the backing nut installation a snap.

Here's Red stripped down to the essentials. The inner fenders have brackets and holes specific to the diesel, so they are removed for the conversion as well. 2F gas motor frame tabs are still present.

The power steering lines are removed all the way to the gear, as the pump is mounted in a different position on the diesel motor and the hoses are routed differently.

On Red I took a few extra minutes and resealed the transmission front retainer. It was a good thing too. The seal lip material was hard as ceramic!

Right motor frame tab cleaned and the area prepped for the installation of the diesel motor tab. I put a small hole in the frame on this side, but I'll fill it up with weld. It wil be just fine.

Left side prepped. This tab gets a greater amount of movement. Note all the holes to act as datum points for pre-installing the tabs before dropping in the diesel.

Here I hot glue gunned on the right side diesel motor tab to the frame. The heat color indicates good penetration and I was pleased with the results.

View of left tab from the front. These mounting tabs were cut off of the "donor" truck and cleaned up for installation on Red.


Right tab from the rear.

Left tab from the rear.

With the frame tabs welded in, I had a place to set the motor. After painting the new frame tabs, I placed the motor in place and got busy with the fuel system, exhaust piping, clutch hydraulics, cooling system and throttle cabling. This is the "glory" work and goes pretty fast.

The fuel system required the greatest amount of materials transfer. Without a whole donor vehicle there is no way I would have had the correct pieces on hand to accomplish the conversion. The fuel filler, vent tubing, and the fuel feed line were all distinct to the diesel.

The vapor recovery device in the rear quarter panel is the same part number. This was good news for me 'cause the diesel rig unit was rusted piece of refuse! The filler neck and filler cap were something I never would have thought of if I tried to do the conversion by ordering parts.