Author Topic: Gen 2 Engine Swaps - Knowledge Dump  (Read 4713 times)

engiekev

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Gen 2 Engine Swaps - Knowledge Dump
« on: September 12, 2017, 05:13:50 AM »
In trying to determine all the various engine swap possibilites for a Gen 2, I didn't find a single thread that compiled all the info for all the various swaps possible (unless I missed it!) Making this thread for a knowledge dump of resources and experiences on engine swaps into Gen 2 vehicles. 

General Engine Info

Montero Engines

3.0L 6G72 SOHC 12V 1991-1995
151 HP
174 ft-lbs
Pros:
-Cheap?
-OBDI
Cons:
-Least powerful engine offered in gen 2s
-6G72 block/heads/parts not interchangeable with 6G74


3.0L 6G72 SOHC 24V 1996-2000
177 HP
188 ft-lbs
Pros:
-24V improves power over 12V 3.0L
Cons:
-6G72 block/heads/parts not interchangeable with 6G74
-OBDII, more diagnostic sensors

3.5L 6G74 DOHC 95-96
213 HP
228 ft-lbs
Pros:
-Top-end power, and power potential
-DOHC cool factor  8)
-Parts interchangeability with 3000GT/Stealth engines (turbos!!)
Cons:
-Complexity, reliability, cost vs. SOHC
-Powerband for offroading (higher in RPM range than SOHC)
-OBDII with a multitude of diagnostic sensors

3.5L 6G74 SOHC 96+
200 HP
228 ft-lbs
Pros:
-Most desirable for 3.0L vehicles
-Simple and reliable
-Many applications for engine parts compatibility
-6G75 crank fits in block for stroker engine (would need new pistons?)
Cons:
-Less HP and top end than the DOHC 6g74 variant (and less cool factor!)

3.5L 6G74 2001-2003
200 HP
235 ft-lbs
Pros:
-Slightly more torque than Gen 2 3.5L SOHC
Cons:
-Wiring complexity

3.8L 6G75 2003-2006
215 HP
248 ft-lbs
Pros:
-Most powerful engine offered in Monteros
-6G75 crank fits into 6G74 block
Cons:
-ECU and TCU integration (? confirm) may necessitate swapping engine and transmission together, along with wiring harness for both systems. 
-Cluster from Gen 2 would need modification to work with CAN bus system, aftermarket tach/speedometer may be easier, or CAN bus display
Resources:
https://www2.pajeroclub.com.au/forum/showthread.php?t=40816
https://www.rpw.com.au/6g75-engine-conversions-now-available-5-september-2011/
http://forum.expeditionportal.com/threads/149274-Gen-2-5-3-8-Swap

Non-Montero Engines

3.5L 6G74 SOHC 96+ Montero Sport
200 HP
228 ft-lbs
Pros:
-Easy to find!
Cons:
-Some wiring harness differences possible?

3.8L 6G75 MIVEC 2006-2012 Eclipse/Galant
263-265 HP
260 ft-lbs
Pros:
-Highest HP 6GXX offered in US
Cons:
-Possible conflicts with engine accessories going from a transverse mount to longitudinal
-Likely uses CAN messaging for engine and transmission signals
Resources:
http://4x4wire.com/forums/ubbthreads.php/topics/1038626.html

JDM Engines:


6G74 DOHC MIVEC 3.5L (Pajero Evo)
276 HP
256 ft-lb
Pros:
-Evo Power!
Cons:
-Cost, complexity, parts are rare


4D56T Diesel (Intercooled variant) 1992-????
136 HP
236 ft-lb
Pros:
-Diesel torque
-Turbo!
-Available in Gen 2 JDM vehicles, swap would be easy with engine, harness,
Cons:
-Accessory parts are unique to 4D56T (intake air box, etc.)
-Requires finding a complete donor vehicle to make swap feasible

Non-Mitsu Engines

Toyota 1UZ-FE Engine
251-300 HP
260-310 ft-lbs
Pros:
-Potentially bolts onto gen2 transmission (confirm?)
-V8 noises
-Toyota reliability
Cons:
-Timing belt
Resources:
https://www2.pajeroclub.com.au/forum/showthread.php?t=23804
http://www.pajeroclub.co.za/forum/viewtopic.php?f=31&t=4099&sid=565eb9229e64266028460d516b1fb5bd
http://www.offroadexpress.kiwi/Forums/viewtopic.php?t=39108

LS1 5.3+ 1996+ Anything Chevy
270-315+ HP
315-338+ ft-lbs
Pros:
-Plentiful
-V8 noises
-Cheap
Cons:
-Requires full swap of engine, transmission, transfer case, custom driveshaft.
-OR custom transfer case adapter ($1000+) to adapt 4L60e to 31 spline transfer case
Resources:

This is just starting point, please post to correct errors and add info and I'll update the main post. 
« Last Edit: September 18, 2017, 06:28:33 AM by engiekev »

ThePug

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #1 on: September 12, 2017, 09:28:05 AM »
Cool thread

Shovel

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #2 on: September 12, 2017, 09:52:25 AM »
Rumor that I have not yet been able to confirm, this is just intended to get the idea out there.    I will edit it if/when new data becomes available.

I have read that almost all Hyundai engines are physically compatible with the 6G7* bolt pattern/shaft.    That would include the 3.5 in Kia and Hyundai rwd SUVs,  the 4cyl engines (a turbo 4cyl should be pretty close to a Mitsu 3.5 in power while being lighter and possibly more fuel efficient when you're not using that power)..     Kia Sorento engines are plentiful,  and if Lambda engines from Hyundai Genesis are compatible that's a turbo 4 and a kick ass 3.8 v6 you can pick up relatively cheaply if you can work out the electronics.     Since both of those are available as crate motors from Hyundai the electronics should be documented too. 

Also,  thanks to that time Dodge was selling the Mitsu 3.0 alongside their own V6 in minivans 25+ years ago I believe a lot of more modern Chrysler/FCA/Jeep V6 engines might be pattern candidates. 
« Last Edit: September 12, 2017, 09:54:12 AM by Shovel »

RXIN HED

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #3 on: September 12, 2017, 10:24:14 AM »
Don't leave out the Sport-era 6G72 like in my 02 parts car
1988 Max SPX Extended Cab 4wd with Service Body & Starion Power
1980 Dodge W400 service truck

For Sale: 1983 Montero #277, 1989 Power Ram 50 extended cab
Sundry Gen 1 Montero and Gen 1 & 2 Mighty Max parts and vehicles for sale

kalieracer

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #4 on: September 15, 2017, 07:29:41 AM »
3.8 6G75 Mivec will also swap in.. 263hp 265tq.. Headers and cams on that motor will bring it to about 300-320....  I am working on getting the electronics part to be a drop in for 94-2000 trucks.

concealer404

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #5 on: September 15, 2017, 08:18:23 AM »
3.8 6G75 Mivec will also swap in.. 263hp 265tq.. Headers and cams on that motor will bring it to about 300-320....  I am working on getting the electronics part to be a drop in for 94-2000 trucks.

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1998 Montero Winter Package (Mine)
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kalieracer

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #6 on: September 16, 2017, 10:41:26 AM »
I am working on a project for plug and play engine managment for 89-2000 trucks, that will allow you to drop in a motor and wiring harness and have full tuning, ODB II , Emissions monitors readiness and the ability to run any 6g74 /Sohc / Dohc / 6G75 and mivec and add knock control and also be able to use the variable intake manifold from one ECU and will plug in to the stock 94-2000 harnesses (Fed and cali)

ChargerX3

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #7 on: September 16, 2017, 04:19:07 PM »
I've got the 3.8l 6g75 MIVEC in my 1990 Mighty Max. I don't think your options get any better than that. Everything bolt up just fine. One side of the block lacks a few motor mount bosses but there are ways around that.

Wiring harness isn't that bad either. I opted to use the existing one with my car and just ran a few extra lines for other circuits like knock, temp, o2, etc. I just made a conversion harness that clipped into my existing one. The real key is using the correct ecu. 98-99 montero and sport guys are in luck. You are perfectly poised to do virtually any 74 or 75 swap.

kalieracer

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #8 on: September 17, 2017, 07:01:32 PM »
The 3.8 swap is going to next on my list. are the bosses cast in and just not tapped?

I've got the 3.8l 6g75 MIVEC in my 1990 Mighty Max. I don't think your options get any better than that. Everything bolt up just fine. One side of the block lacks a few motor mount bosses but there are ways around that.

Wiring harness isn't that bad either. I opted to use the existing one with my car and just ran a few extra lines for other circuits like knock, temp, o2, etc. I just made a conversion harness that clipped into my existing one. The real key is using the correct ecu. 98-99 montero and sport guys are in luck. You are perfectly poised to do virtually any 74 or 75 swap.

engiekev

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #9 on: September 18, 2017, 05:40:51 AM »
Is the 6G75 MIVEC available in any US sold car? I'll update the list

I've got the 3.8l 6g75 MIVEC in my 1990 Mighty Max. I don't think your options get any better than that. Everything bolt up just fine. One side of the block lacks a few motor mount bosses but there are ways around that.

Wiring harness isn't that bad either. I opted to use the existing one with my car and just ran a few extra lines for other circuits like knock, temp, o2, etc. I just made a conversion harness that clipped into my existing one. The real key is using the correct ecu. 98-99 montero and sport guys are in luck. You are perfectly poised to do virtually any 74 or 75 swap.

concealer404

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #10 on: September 18, 2017, 06:03:31 AM »
Eclipse, Galant.
1998 Montero Winter Package (Mine)
2003 20th Anniversary Montero (Wife's)

ChargerX3

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #11 on: September 18, 2017, 03:30:26 PM »
The 3.8 swap is going to next on my list. are the bosses cast in and just not tapped?

I've got the 3.8l 6g75 MIVEC in my 1990 Mighty Max. I don't think your options get any better than that. Everything bolt up just fine. One side of the block lacks a few motor mount bosses but there are ways around that.

Wiring harness isn't that bad either. I opted to use the existing one with my car and just ran a few extra lines for other circuits like knock, temp, o2, etc. I just made a conversion harness that clipped into my existing one. The real key is using the correct ecu. 98-99 montero and sport guys are in luck. You are perfectly poised to do virtually any 74 or 75 swap.

The passenger side is missing the rear 3rd mounting boss completely. Wouldn't be so bad but the other two bolts are on the skill side. No good.

kalieracer

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #12 on: September 18, 2017, 08:31:29 PM »
How did you end up over coming the the issue if you don't mind sharing?

The 3.8 swap is going to next on my list. are the bosses cast in and just not tapped?

I've got the 3.8l 6g75 MIVEC in my 1990 Mighty Max. I don't think your options get any better than that. Everything bolt up just fine. One side of the block lacks a few motor mount bosses but there are ways around that.

Wiring harness isn't that bad either. I opted to use the existing one with my car and just ran a few extra lines for other circuits like knock, temp, o2, etc. I just made a conversion harness that clipped into my existing one. The real key is using the correct ecu. 98-99 montero and sport guys are in luck. You are perfectly poised to do virtually any 74 or 75 swap.

The passenger side is missing the rear 3rd mounting boss completely. Wouldn't be so bad but the other two bolts are on the skill side. No good.

ChargerX3

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #13 on: September 24, 2017, 11:21:23 PM »
I welded a cast boss to the block. Wasn't easy as cast first like being welded.

MrGalantguy

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Re: Gen 2 Engine Swaps - Knowledge Dump
« Reply #14 on: September 27, 2017, 08:08:43 AM »
Definitely keeping my eye on this topic especially the 75 drop in package kalieracer is working on.

This is something I plan to do down the road. 8)
-1998 Montero (Winter package & Adjustable suspension)
-2002 Montero Limited
-1991 Galant VR4 1948/2000
-1996 Galant 4G64t 5spd
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