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This is an information dump regarding the engine swap I recently preformed on my 1999 Montero (3.5 SOHC, automatic)

The engine swapped into this 99 Montero is from an 04 Galant, it was originally a front-wheel-drive transverse mounted engine. Changes need to be made in order to use this engine longitudinally. I will attempt to cover these changes in the information below. This thread will evolve and this first post will be more updated as time goes.

Previous discussions on various forms of 3.8 engine swaps can be found here. While that thread is a great source of knowledge, it covers a lot of variations of engines and chassis applications which can bog you down with data. Since the 97-99 chassis is so commonly swapped, this thread is dedicated to that specific swap.

This thread will cover installing a 3.8 fwd engine into the 97-00 Montero chassis. The 3.8 engine is the same deck height, the larger displacement is achieved with a longer throw crank and different pistons. The cylinder heads on the 3.8 also have larger valves and larger bowls. Mechanically you're just doing an air displacement upgrade.

This swap was started with a 2004 3.8 engine, stripped down to just the long block, using the 3.8 cams and practically everything else from the 3.5.

Here's a list of hardware I swapped over.

-valve covers from 3.5 (3.8 had coil on plug, not this time around)
-driver side 3.5 rear cam plug, 3.8 had a cam sensor on the 'rear' of the driverside head, removed along with the flywheel, replaced with oem plug
-driver side 3.5 cam gear and timing flywheel for the 3.5 style cam sensor (passenger cam gear on the 3.8 is the same as the 3.5)
-Timing shields that bolt to the heads, no mods needed
-3.5 crank sprocket and timing flywheel
-3.5 crank and cam sensors
-timing covers from the 3.5, bank 2 needed a small notch cut in it using a dremel.
-lower intake plenum from 3.5
-fuel rail and injectors from 3.5, the injectors are lower flow rate than the 3.8, so you may need to run premium fuel, havent verified lower octane works yet but mine works on premium fuel. (15,000 miles of use later, premium yields great results)
-3.5 water pump assembly and water plumping, rear cross over tube, 1" valley tube, 2" upper return tube and thermostat housing from the 3.5
-Oil pump from 3.5, this sets the timing tensioner angle, be careful when buying new as many companies sell the wrong pump with incorrect cooler mounting orientation, i re-used my oem one since it was in spec still
-3.5 timing tensioner arm, hydro tensioner, tensioner pulley and idler pulley with spacer
-3.5 oil pan, two holes will need to be drilled in the block, its easy and will be covered with photos
-3.5 engine to trans plate and flex plate
-3.5 engine mount brackets, some bolts line up, some dont, a little drilling and the making of a small spacer should cover it.

For Sale Automotive / 15x10 & 15x8 wheels
« on: February 19, 2018, 10:23:56 PM »
both sets sold. thanks.


1979 Mitsubishi Galant Sigma Wagon - Touring ( if I had to classify it.)
(Title reads Dodge Colt, Mitsubishi wasnt positioned in America yet, car is 100% Mitsubishi factory produced, shipped over, added dodge badges, sold as dodge.)

- Old and tired, but reliable 4G54 2.6 Liter Single cam, timing chain with silent shaft engine, with Weber 32/36 carb
- Great shifting KM132 5 speed trans (cable clutch)
- Rear is coil sprung instead of leaf like previous generation
- Larger bodied than gen 1 Colt/Galants
- Everything works including the air conditioning!
- Interior is old and dry but mostly complete, it shows it's age, like the exterior does, 99% of things function.

This Sigma is mostly stock, well sun-baked and patina'd. Could easily be painted, I've chosen to polish the patina and embrace it as a 'Survivor car'. Some aesthetic upgrades and wear parts have been replaced. I daily drive the wagon around town when I work from home and need to run errands or ship orders... every few weeks I drive it 50 miles to work, which is an hour-plus each way across Phoenix, I do this year round, when it's cool enough to need the heat and hot enough to need air conditioning. The wagon is not my primary vehicle but has always been reliable and even on 115 degree days has made it's way across the valley, pumping AC. I do this to keep tabs on itís reliability, plus it's fun to drive.

I bought this car after it was found in Prescott back in 2015... The old wagon lived it's entire life in the small mountain town area. Back in the 70's there was a small dodge dealer who sold a lot of the Mighty Max, D50, Gen 1 Montero's and quite a few of the Colt, Arrow and Challenger cars, later the Conquest too... All made by mitsu, all shipped in from japan and all wandering around northern Arizona. Every year I see one or two unique cars pop up. This is one of only two sigma wagons I know of. I've only ever seen two for sale or running and I know the owner of the other car.

I assume John Baker had something to do with all the Arizona sales, he was racing around here back them. If you dont know who he was; google him, but he was a sponsored race driver of the mighty max and other chassis back in the day, even had a company making parts for monteros like we do these days

The wagon started and ran when found, an old battery in it with dirty terminals, the old battery took a jump start and the car came to life, that battery still powers the wagon currently... I dont trust is so I carry a brand new battery and some wrenches in the back, but my curiosity makes me leave that ancient battery in place. I want to see how long it goes... anyhow, the car had been sitting since roughly 2006, I determined that by the date codes on the full tread tires it had and the receipts for a tune-up inside the car... After almost ten years of sitting in a dry, dusty carport, it was driven down to the Phoenix valley. Which is mostly just a downhill cruise to the valley...

 I did a tune-up, new NGK plugs and wires, the engine is basically an 80's mighty max, wide block 2.6, flying magnet style distributor, cap and rotor, I converted the AC system over with new R134 freon, added brand new 15x8 wheels, new yokohama tires...

Then I drove it six-plus hours straight across the desert in the hottest month of the year to LA, for Mitsubishi Owners Day in 2016. This old wagon was loaded with 3 people and outfitted as a sleeper, meaning a memory foam mattress-topper and blankets folded up in the back, (still in there, still like to camp on graded forest roads, the back seat folds down flat) the whole assembly is about the weight of a small person or child, we had two tool bags in the back seat with the passenger. On the roof rack was an extra spare tire because ive had I10 eat my tires before, a large 70's water canteen for drinking water just in case of breakdown and a 70's folding rocking chair, for sitting, of course. We camped at mitsubishi headquarters, enjoyed the show, then went canyon cruising with the only two classic mitsubishi's that made it out. Japanese nostalgic car wrote about it in the link below. After grabbing grub with the group we drove back across the desert in 100+ temps with the AC going the entire time, sun at our back... The car has a 3 row metal radiator from the dealer in Prescott. Possibly where the Weber carb came from, it looks like an older model and I bet that dealer was a John Baker parts dealer as well... We rolled into the phoenix area around midnight. The wagon consumed some oil and needed a quart with every fill-up when driving 75 constant down the highway, up and down small grades... but, it was quite loaded down, and regardless, the entire thing went smooth as silk, even climbing the steep grades on highway ten leaving the Coachella area. The 2.6 pulls very strong despite needing service. It's climbed many a 7% grade and kept up with the flow of traffic. I would love to drive it cross country but my focus is on work related projects.

Article I mentioned:

Replacement wear parts and upgrades:

KYB GR2 Shocks all around (Bilsteins are still available!), new front brake pads, 4 Rota 15x8 wheels with decent Yokohama 195ís. Dual knob old school style radio with USB mp3 input. NGK plugs and wires, new mechanical fuel pump, new fuel lines and filter, new fluids in general. Front lip, JDM fender mirrors. Super dark tint all around, 5%, some officers have said 2%... Has a dashmat to cover the dry and cracked dashboard. Front seats have seat covers, need to be replaced or redone. 

Comes with a decent amount of new parts, timing components, header, gaskets, almost everything to freshen the engine up. Any other parts needed are available on rock auto for pretty cheap. This car has been living in an arid environment for almost 40 years... so it leaks a tiny bit of oil and burns oil, mostly at highway speeds. Itís pretty good around town or under 45mph, hardly consumes any oil, but above 45mph... and the car will cruise, at 75mph it will easily go with the flow of traffic here, but the engine is able to pull enough vacuum at that RPM to consume oil. I don't know if it's rings or valve stem seal, I suspect stem seals due to the dry climate, but my plan was to re-ring the engine with new seals and gaskets, mitsu cylinder walls are usually in mint shape but the rings will wear, and long before the cylinder walls show wear. Otherwise the torquey motor runs really smooth. I only planned to have this engine in use until I swapped a 2.4 fuel injected engine from a mighty max. That was all long-term goal stuff though...

I dont want to let this car go, but Iíll still be around vintage japanese cars, my girlfriend still has a 75, so Iíll get my jnc fix from that, I need to focus as much of my time effort and money on my 4wdís as I can. There are miles to cover in the years to come. I have to consolidate into a single, extremely well equipped vehicle, instead of 7 running and driving projects.

Price is $4500 OBO, No trades. Iíd drive this car across country in a heartbeat, Ive driven two, older, much less reliable wagons on similar adventures, if you keep oil in oleí Rose... sheíll go forever. Thereís two airports near my house and I can pick up anyone willing to drive some old classic metal across the country or I am willing to be available when a shipper picks it up. The e-brake works, all the safety and standard equipment works, the car is ready to go. Two people under 6'5" can easily sleep in the back of this thing. Comfortably. If I was me 6 years ago, still living in the midwest, I'd be buying tickets to fly to the southwest with my girlfriend for another cross country adventure in an old wagon... But, she's got her wagon, so we'll cruise cross country with hers. I can take as many photos or videos needed of this thing. Just posting this now because I keep putting it off and keep saying I'm gonna do it.

Reasons you want this:
i'ts awesome, reliable, famous, fun, rare, quirky, cool and fully equipped. Has lots of history. Rust free, straight body with some dings. plates and insurance are super cheap.
Reasons you dont want this:
you want this, or you're probably a wanker, needs some work to be top notch, its old,

Vehicle: 1999 Montero with locker.

Beginning specifications:
Exterior: Sudan Beige
Interior: Tan leather
Engine: 3.5 liter single over head cam V6 "6G74" - Iron block, aluminum heads, timing belt driven
Transmission: Aisin AW03-72LE - overdrive auto transmission
Transfercase: Superselect, 2wd, synchronized shift-on-the-fly awd, Standard 4wd high and low.
Axles: High pinion 8" up front, 9.5" rear with factory air locker, 4.27 differentials

Proposed specifications:
Exterior: Adventure Driven Design Livery - Grey and Blue topography over battleship grey, white top, black lower trim.
Interior: Tan canvas
Engine: 3.8 liter single over head cam V6 "6G75" - Iron block, aluminum heads, timing belt driven, eaton supercharger
Transmission: Aisin AW03-72LE - overdrive auto transmission - shift kit - larger cooler
Transfercase: Superselect, 2wd, synchronized shift-on-the-fly awd, standard 4wd high and Marks4WD 2.7:1 low.
Axles: High pinion 8" up front, 9.5" rear with factory air locker, 4.90 differentials

Day one:

Current: (will change with progress)

Goldi-locker was purchased in LA quite a while back to fill the montero void in our life, after we started ADD, it became a 'stock comparison truck' ... since it wasnt modded we used it for a baseline comparison. I tolerated riding on KYB's and made due with 31" tires, daily drove the truck and showed up to any wheeling trip I could. Showing just how much you can do with a low budget truck.

After 2 years of moderate to heavy use for a stock truck, it has held up great. The vehicle will be an ADD brand ambassador for 2018 so it's time to start working it over. Friday of last week I installed a new denso alternator, new trans lines, added new fluid and put in a fresh-from-the-dealer coolant reservoir. Then stabbed four new Bilstein 5100 long travel shocks and stainless skidplates, total shock install took about two hours, 30 minutes each, I didn't take any of my wheels off and only used a floor jack and some hand tools.

The real trick to installing these long travel shocks is a good long wood working clamp, safety protection of course, and some strong string. I used the wood clamp to compress the shocks, tied them off with the string and popped them in. The trick to removing the stock shocks was to tie them off with the vehicle at rest, remove the top nuts from the fron and rear, then jack the truck up and undo the bolts, they remain compressed and slip out nice and easy. All in all, it went well.

Saturday I went out with the local crew to some rocky trails, the 5100's ride very plush, they soak up terrain and make washboard roads feel like mall parking lots. I was so impressed with the quality of the ride, i decided I wouldnt air down my tires so I could see just how nice the Bilstein 5100 is compared to a KYB... I did the same trail a year prior with the same truck on KYB's and it beat the shit out of me, I even aired down on that run.

The whole day went smooth, the ride was good even with the tires at full pressure, but the trail kept getting rockier and rockier, at one point as we casually strolled through a rubble road I said to myself, or maybe to my co-pilot CJ "I think I should air down" - but we were almost to the secret lake, so whatever, I'll be fine, the exit is right after the lake anyho-PSSSSH 'oh shit, is that us? That's us!" PSSSSH rear tire encountered a very sharp knife edged rock with the sidewall. My tires are Yokohama Geolander A/T-S in 31x10.50R15 on some 15x8 turbine wheels, perfect for a stock truck, especially a gen 2.5 with 4.27 gears... After swapping on the spare I caught back up with the gang and it was decided, Ive got the front 4.90's, the rears will be here soon, it's time for 33's...

I've got a lot going on guys, but im trying to clean out my garage to house ADD inventory, got the security system set up, getting shelving this friday... but... I've got to get rid of a TON of stuff.

I'm going to try and post at least one item or more each day, prices are fairly firm, because they're already gonna be low.

Starting with:

new-in-box Daystar Gen 2 coil spring spacers, these are 2.5" spacers, local dudes have run them, so i know they work.

They're originally for sequoia, if you want a photo and youve got my number, text me, but c'mon, i just said they're brand new in box, still have a sticker in the box. Part number KT09111BK

Buy them on the internets for $100, buy them from me for $66.69 shipped.
paypal is - first to pay gets them, if this post is still up, I still have them.

I'm terrible at replying to private messages, texts, emails and I never answer my phone if I dont know the number, so if you need some hand holding, close this tab.

Other items I have that I can think of immediately:

pair of 1994 Montero LS headlights, glass in great shape, these are the pre-97, fluted lenses. Great for a midwesterner looking to replace with some rust free southwest parts.
$88.77 shipped

1994 LS Battery tray and fender bracket, replace your rotted out rusty piece of shit, or, use it for an easy add of a second battery (dont think because I said this that I know it fits, you'll have to use your brain, if you ask me where to put it, ill reply with a really clever answer) $33.33 shipped

Aftermarket (maybe ebay?) Gen 2 94-96 LS or SR front fender flares, these puppies are hella JDM, not really, they're just some poly, maybe fiberglass, i cant tell, aftermarket flares, i'll snag a picture of these because they're hard to explain, they mount using screws, so be prepared to fuck your shit up. They're black in color and it's only the front pair, i basically want you to cover shipping on these or I will smash them into pieces and throw them away, sick of looking at them.

More to come, a lot of this will have a drop-dead date, if its not sold by the end of January, i'll be scrapping it.

If you're looking for Gen 2 parts, ive got some gray interior bits, misc handles, relays, plugs, and all sorts of bullshit in totes, i have the break them open and lay them out on the floor, so im trying to clean up the floor right now.

By now many of you have downloaded our official buyers guide. You've probably noticed it's a little incomplete and has some filler material in places that could use more detailed information. There's some errors and typos, but, all in all, for something that Brian Driggs was able to piece together in a matter of hours, the night before MOD2017, it's pretty darn good.

If you haven't seen it, you can get your copy here:

This thread is for general revisions and to help expand on individual topics. I ask if you're going to contribute information, please provide any source you can on it. We'll start with the overview of the Montero:

The mountain hunter. Seriously. Thatís what it means. Of course, in most other markets outside North America, itís called by its real nameó Pajero. In the UK, itís called Shogun. Why the different names? Well, as it turns out, Pajero might be a name for the Pampas Cat, a smaller feline predator found in Patagonia, itís also Spanish slang for, um, letís just say ďwanker.Ē

A  little  history,  in  celebration  of  their  100th  anniversary,  the  Mitsubishi  Model A sedan was the first mass production car in Japanese history way back in 1917. By  the  way,  in  case  youíre  thinking  they  copied  Henry  Ford,  weíd  like  to point out Fordís Model A wasnít introduced until 1927óa full decade after Mitsubishi. Funny, that. Then, in 1934, Mitsubishi developed the first Japanese-built sedan with full-time  4WDóthe PX33. Pretty neat, right? But wait! Thereís more! Starting  in  1953,  Mitsubishi  built  Jeep CJ3s. And they continued to do so until 1998. Thatís right. If you can find one, you can likely legally import an old school Jeepówith a Mitsubishi turbo-diesel engine.

The Pajero first hit the autoshow circuit as a prototype in 1973. The first
gen (aka: Gen 1, we donít do that 1G/2G/3G stuff) hit showroom floors
in 1982. A year later, the first Pajero would enter Dakar. It would become
the most successful vehicle in Dakar Rally history, winning 15 of the last
32 races.

Oh  yeah,  and  the  4WD  system  in  all  those  Evos?  You  can  trace  its 
history all the way back to the Pajero drivetrain they stuffed under a
Starion back in the late 80s to go Group B rallying.

General Discussion / Montero Monday - Aka 'post your montero pics'
« on: July 27, 2017, 04:53:56 PM »
Hey all! We are  going to showcase Monteros through our social media outlets and, at the same time give  you guys free stuff!

if we get over 50 submissions a cycle (2 weeks), we'll give out a  prize to whoever gets their photo  chosen for Montero Monday.

Because who doesn't love free stuff, and you're helping to grow the awareness of how awesome these trucks are. So thanks for that.

Some rules to get things started;

Aug 7th will be the first Montero Monday giveaway. First prize up for grabs will be a set of Siberian bushings upper or lower control arm bushings. (winners choice)

3 Submissions will be chosen randomly, then voted on by judges. Choose some great shots and submit a few. (please limit to 5 total photos per user, per cycle, photos can be submitted more than one cycle if not chosen)

You can find us on instagram and facebook by the links in my signature. Posting on social media requires a couple of extra steps:
You must be following us/like our page
You must tag us in your post
You must use hashtag #MonteroMonday
(We need to be able to find you again, obviously)

Post 'em if you've got 'em. 

Monteros, Montero Sports, Gen 1 Raiders and 4WD Mighty Maxes  are eligible to submit to this context.

Other 4WD / AWD MITSUBISHIS are welcome to submit, cars  chances of winning will be in relation to their  ground clearance. lol

my 99

Phil's paj-evo

Justice' gen 2

Gen 2 Montero / Gen 2 Heater Core Replacement and differences
« on: July 19, 2017, 12:34:55 PM »
I'm starting this thread as a bit of a place-holder. I'll be ripping into my Gen 2.5 Montero (1999) and replacing the heater core this fall... there's been some discussions among local crowds, sometimes internet folks about the timeline of Gen 2's, mitsu might've been cutting costs as time went on, taking lower bids on out-sourced parts.

If you know much about auto manufacturing, you're probably aware of what it takes to make a vehicle, heater cores and radiators and intercoolers from these guys, shocks from those guys, ignition parts from those other dudes, transmissions often from somewhere else, it all comes together and youve got a working unit, over time if that unit proves popular, especially if it's cult level popular, you're able to retain the same chassis and drivetrain but cut costs through writing specs to bid or reverse engineering and producing things in-house. it's a churning industry with too many cooks in the kitchen and often far too driven by the accounting department.

It's often been said that when accounting wins against engineering in the argument for a product the consumer ends up losing. this is almost always the case, but even when engineering wins, the customer still suffers because the higher costs of the quality parts are marked-up and passed on to the consumer. So you either pay up for good stuff or pay little for future effort/costs.

Almost every Gen 2.5 I come into contact with ends up needing a heater core at some point. Most of the southwest guys have theirs blocked off. This is fine for 9 months of the year, for 3 months or northern trips, or major road trips, it will suck a bit.

The idea I have is to pull the heater core from my 99 and retrofit a 1994 unit after comparing them, I'll be documenting the differences and probably going to a local radiator shop to have the 1994 core beefed up a little, if possible.

If any of you have any current documentation on heater cores for gen 2-2.5's or you can share a photo of one you've removed from a truck, maybe your truck, please feel free to post, the info that would be good to share is:

Year of montero
Did the unit fail?
Manufacture if stamped on end tank
detailed photos of the seams

1984 Dodge D50 2.3 liter turbo diesel, 2wd, 5 speed

   Moving to the desert takes some adjusting, I parted ways with my 96 SR on 37's when I left the splendor of Michiganís West coast. I figured I would find a lot of rust free cars in the southwest. I didn't expect to be smacked in the face with every single example of a Mitsubishi I've ever wanted to own. From cars to trucks and everything between, I ended up feeling like a kid in a candy store.

 Before moving I planned to do a mighty max build of some kind using gen 2 parts, but I expected to be a year out before that would start. As things work out, I was just hitting the year mark when the diesel mysteriously came into the works... It was formerly owned by an older couple in southern california, then later moved to southern Arizona, it came clean as a whistle, loaded with all the options, AC, cruise control, tachometer, digital clock, wastegated turbo, and every bit of fuel mileage you could ever want it became my daily driver for quite a few months. In the initial phase it looked more like "Gramps fishin' truck" than a carcass-devouring filthy mutt, but that's all set to change...

There's been a lot of Mitsubishi work happening on the outskirts of the Tonto National Forest, under the shadow of the Superstition Mountains... they're everywhere and they're all getting chopped up and modified heavily. A 4x4 chassis was prepared for the Hyena, it came from an 82 that was running a 2.6 gas engine and 3 speed a904 trans, 8" rear with 3.90 open diffs, the rolling chassis came from Toasty, but it's now equipped with 5.29 gen 2 montero front and rear with a locker, montero coil sprung suspension, trailing arms,  all new steering parts, v6 torsion bars, a 4 speed AW03-72L and an NP231 transfer case. Most of which were scraps from builds around the valley. The 4D55 from the truck will be powering the chassis and it will be equipped with Western Wheels 15x10 cyclone II's and 35" tires with tube fenders for it's 4x4 initial phase.

Stay tuned...

How things started. I'll miss this configuration, 40mpg, versatile little truck.

It's like a 4BT but more obscure. The injection pump is practically the same as the Bosch unit found on the 4BT, it was licensed by them.

That time Toaster and I made a 15 foot tall A-frame hoist to lift the body from my truck and then I used it once.

Here we see the Mighty Max leaf sprung suspension compared to a 94 Montero LS suspension. Getting 5.29's for my truck was awesome, coil suspension was a bonus. Lucky for me Toast is a surgeon with metal cutting devices. I dropped the truck off and he returned it to me looking like a factory coil max... I'm always really impressed with his metal work.

As you can see, even with 33's there's trimming to be done.

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