Jeff tries to make a hot rod out of a farm truck. '92 Mighty Max

[Jeff V.]

The V77 intake is overall more massive, and tall in a lot of places the K99 intake isn't, but the highest part is only 0.25" taller than the top of the EGR valve on the K99 intake. The rough average difference in height is around an inch.

[Jeff V.]

I borrowed this from your YouTube video. Yours isn't even close to the top of the firewall.

[ChargerX3]

Wow seemed like more than an inch. Looks can be deceiving. You should clear just fine with only that slight increase.

[Jeff V.]

I've made a decent amount of progress given how little time I've had to work on the engine.

It looks like the Montero intake will fit just fine with a 1/4" spacer. I'm going to order some teflon sheets and make something up. Grinding it would be a lot easier, but I really want to keep the provisions for the support bracket and EGR flange under the throttle body.

I've also made good progress on the AC compressor bracket. I just need to make some aluminum spacers and an adapter bracket for that.

The motor mounts are also very close. I think I'm only going to have to weld one tab on. Interestingly enough, the 3.0 brackets fit better than the 3.5 parts do. This is good for me because it should just drop right into my frame without any other mods.

I'm wondering how important this will be in the long run.

This is one of the cylinder heads, with the gasket still in place. Note how the gasket is almost perfectly matched to the huge intake port.



This is the 3.8L Montero lower intake manifold, with the same gasket. Note the significant difference in port size.



The 07+ MIVEC Pajero has a different part number for the lower intake. I'm guessing this is why.

This isn't going to be some balls out race truck, but I'm still left wondering how much power this is going to rob me of.

[Chris GTO TT]

[quote=""Jeff V.""]
This isn't going to be some balls out race truck, but I'm still left wondering how much power this is going to rob me of.[/quote]

Why not?

[DCIV]

So take it somewhere and ask them to gasket match it for you. Or mark it and at least get a dremel out and round off the edges.

Are you going to take the pan off and check the bearing clearances on the new motor?


Coop

[Jeff V.]

I have to swap the oil pan anyway, so I'll check the rods while I'm in there.

I've got air tools. I can cut the manifold down myself. I may practice on my 3.5L manifold first.

[DCIV]

I played around with my old lower intake many just to play. It's stronger than I thought. Even if you just round off the edges it would help air flow a lot.


Coop

[Chris GTO TT]

When you go to modify it make sure you use tools/bits designed to cut and grind aluminum. Most of the time bits and grinding disks are designed for either steel or aluminum but not necessarily both.

[Jeff V.]

Thanks. I've run into that before. The aluminum tends to clog up bits not meant for it.

[ChargerX3]

Hmmm your lower intake does look to restrict more than I recall my diamanté doing. Would be worth a gasket match especially since our motors make hp in the upper rpm range.

What are you going to do for your knock sensor? Keep the MIVEC one or get a 3s? They are different part numbers. I kept mine but I have yet to push the engine far enough to see it log any knock yet.

[Jeff V.]

I think they only reason they're different part numbers is because of the length of the cable. I'm going to keep it as-is.

For phase one, I won't be using it anyway. I'm still going to run it with the 3.5L Montero ECU and intake until I figure out the Eclipse stuff.

[Jeff V.]

Nothing like putting in a huge parts order at Rock Auto and realizing you forgot injector o-rings :d oh:

Oh well, at least I don't need them right away.

[DCIV]

I do that SOOOO much.


Coop

[ChargerX3]

You talking about the top o-rings? Can't say I've seen those ever go bad yet. Bottoms yes. Running 360cc injectors?

[Jeff V.]

You talking about the top o-rings? Can't say I've seen those ever go bad yet. Bottoms yes. Running 360cc injectors?

The rings on my injectors are pretty dry. It's cheap and easy preventative maintenance. I'm going to run whatever came with the 6G75. I think they're 305cc.

I spent some time massaging the Sport cam sensor to clear the coolant crossover pipe. I ground off a ton of material from the sensor carrier and the flange on the sensor itself. I can barely get a piece of folded paper in between the sensor and the coolant pipe, but at least it fits now.



Tomorrow I'll get to work on the drivers side motor mount.

[ChargerX3]

That is tight! I think it's even tighter than mine. I don't remember having to grind mine but it was tight and there was no additional room to rotate or install the sensor.

They are 305 injectors. The harness is different and the injectors are shorter. I couldn't use them with my lower intake setup but yours might be different. Might be a perfect fit

[Jeff V.]

You used the crossover pipe from the full size Monte, didn't you? That one was meant to fit with this sensor.

I've got the harnesses from the 3.5 and 3.8 engines, so connectors aren't an issue. The actual mounting points are the same between the old 3S style injectors and the newer ones. The older injectors just have slightly longer spray nozzles, so they stick into the intake tract a little further.

[ChargerX3]

I don't recall where I ended up sourcing mine. Looking at my pictures though it's identical to the portion you have pictured.

[Jeff V.]

WTF is he up to now?