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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.

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For Sale Automotive / FS: ADD Hardcore Chromoly Idler King Pin Kit and OEM Idler Arm
« Last post by Zimdoc on March 01, 2020, 07:44:19 PM »
I've got a new in box never installed ADD Chromoly Idler King Pin Kit and OEM Idler Arm ready for whoever is wanting the bullet-it proof steering set up for their Gen2/2.5 Montero.

Parts are located in Portland, OR. Willing to ship, buyer pays for shipping.

For quick response and photos shoot me a text at five03.86zero.286three.

Price $260
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Mitsubishi Related / Re: 2.5 Gen Transfer Case Failure
« Last post by bear on February 03, 2020, 12:15:14 AM »
You can still get the red/brown bushing on
Line , I just received 3 . A little more work.
But it beats not having one .
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Mitsubishi Related / Re: What battery should I get? Or what are you running?
« Last post by bear on February 02, 2020, 11:43:09 PM »
I use a red top Optima.  After one year I had
To get it replaced under warranty.  They work when they
Are good. Lol
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Build Threads / Re: Se7en62's '99 Montero Gen 2.5 Overland Build & Adventures
« Last post by Se7en62 on January 13, 2020, 09:58:25 PM »
Haven't done an update in some time, just due to travel and work and other projects we have going on. I'll update this thread soon, but in the meantime, check out our new short film we produced about this truck and two other Montero on an epic trip across Colorado.  8)

https://youtu.be/ml3Uwniuteo
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General Discussion / Driven Over Land - A Short Film
« Last post by Se7en62 on January 13, 2020, 09:56:28 PM »
A 26-minute overland adventure through the Colorado backcountry with Driven Over Land and our trio of Mitsubishi Monteros. Join us for 8-days, 11 epic passes, and 7 remote camps in 6 nat'l forests. I hope y'all enjoy our short film. It was a ton of work and is our first attempt at capturing the majesty and grandness of the Rocky Mountains.
 
https://youtu.be/ml3Uwniuteo
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Gen 2 Montero / Re: 96 SR tach help
« Last post by misensick on January 02, 2020, 03:24:40 PM »
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For Sale Automotive / Re: Clean 2000 Gen 2.5 for sale!
« Last post by NWAMonty on December 30, 2019, 09:58:30 AM »
I see the CL ad is down. Just curious... how'd the sale go?
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Gen 2 Montero / Fuel Tank/Pump
« Last post by radar56 on December 19, 2019, 05:24:04 PM »
Anyone know where I could look into getting a new tank and maybe pump assembly.  Engine has been running a little rough and was going to check the fuel filter, turns out that isn't going to happen being the pump bolts are never coming out.  The lines look like they could go anyday as well.  Got to love MN!
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Gen 1 Montero / Mitsubishi Montero SAS 2 door
« Last post by Montero506 on December 07, 2019, 04:17:23 PM »
Hello guys!!

Sharing the bit of advance on my project, it started as a 2 door montero I got for cheap, is running the 2.6 gas engine and 5 speed manual, superb engine.
Got wheel spacers and 33s with no lift amazing cars! but well suspension died and there was something needed to be done.... either rebuild or something cool....



Way too deep haha



So here we go!!

Front suspension is a 3 link, lower links on bushing + heims, upper heims for adjustability
Rear suspension, front Discovery II RA super long and will be strong enough
Heim joint steering with a modified pitman arm and a DIY Hi steer for the dana (similar to what is done for the jeep SOA)
Dana 30 and 35 for ease of parts (Ford 8.8 is way too expensive here and kind of rare) got a non C-clip dana 35 for peace of mind
Rubicon Express coils for the front stock cherokee rear
ProComp ES9000 shocks (30 inch)
Reinforced chassis with 1/4 inch plate on vital parts


Will be running 4.88 gears and 35s

Stuff I need to get, Dana 30 posi lock, gearing, tires, lockers and lot more stuff but we are never over right??  ;D

So Pura Vida guys!!














Chris!!

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