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Have you figured out engine mount brackets yet? I was going to loan you my 6G74 brackets to see if they'd bolt to the FWD 3.8 block.

Aren't the later mounts quite a bit different. I really just need the max mounts so the engine sits correctly. Many of the bolt locations are there. I think I counted one missing. The biggest issue looks to be proper depth of the locations. Some are shallower or taller on the mivec.

The Max/3.0 Sport mounts won't work with the 3.5 block. I really doubt they'll work with the 3.8 block. I have both types of mounts.

Check this out, about halfway down the page.

http://www.4x4extremesports.com/mitsubi ... _3.5-2.php

I've seen similar info from a guy who did a 3.5 DOHC into a Raider.

As far as the throttle body clearance goes, why not just add a spacer in between the lower and middle manifolds?

Ah yes, good thread. I have only eyeballed for now, but ill look into it some more this weekend to verify. They didn't look off at all. Not worried about welding a little either if it means my engine sits at the proper height.

The tb spacer is still an option, but im starting to get worried about fitting all this under the hood. I may be screwed. The other option is to possibly run the Max upper intake until i figure things out. It sits much lower and the TB location is much closer to engine centerline.

The Max mounts end up missing half the bolts. I wouldn't consider it to be securely mounted. That's why you have to go with hybrid mounts. The block plate from the 3.5 with the 'legs' from the Max mount. That puts the engine right where it needs to go.

That's why I was daydreaming about keeping the front end of my parts truck as a giant jig. To get the motor mounts right.

I think it'd be a lot easier to weld up hybrid mounts than it would be to modify the block to accept the unmodified Max mounts.

The Max intake won't work on the newer engine. The intake ports are shaped totally different. I've already accepted that I'm going to have to cowl my hood. My intake is going to be taller than yours.

There's very little that's reusable from the old 12V engine. Aside from part of the mounting bracket, my entire 12V engine is going in the trash. The only engine parts I kept from the junk engine are stuff other people wanted to buy. I was content to toss the entire lump.

2-3 bolts on each side i would feel comfortable with. Hybrid might still be an option, but I don't want it to sit up any higher.

I haven't pulled the upper intake, but hearing that doesn't surprise me and hurts a little. I was hoping the ports would line up.

Yea, i was planning to sell my max engine to a local 3s guy, so he could toss it in his base. Still runs like a champ.

Steve wrote:Hybrid might still be an option, but I don't want it to sit up any higher.

Doing hybrid mounts keeps the engine where it belongs. That's what the Sport guy did in the website I linked. Same with the Raider guy.

http://4x4wire.com/forums/ubbthreads.ph ... d/1#import

When we're having these discussions, are you using the engine mounts from your 01 Montero as a reference?

[quote=""Jeff V.""]Doing hybrid mounts keeps the engine where it belongs. That's what the Sport guy did in the website I linked. Same with the Raider guy.

http://4x4wire.com/forums/ubbthreads.ph ... d/1#import[/quote]
That would be great if they did. I'll have to read through this last link. That guy did a lot of work. Even cut his oil pan and cab up. Yeesh!
[quote=""Jeff V.""]When we're having these discussions, are you using the engine mounts from your 01 Montero as a reference?[/quote]

For now yes. I know there are various types depending on trim and year. Mine are bulky on the 01.

That might explain the discrepancy. They're chunky aluminum things. The earlier mounts are all simpler steel. Easy to cut and weld, as shown in the two build threads.

Yea might need to keep an eye out for a pair just in case.

http://www.ebay.com/itm/YL043-2002-MITS ... bL&vxp=mtr

Not bad! I'll double check mine.

Almost forgot I had the SR mounts. Just checked them and they look very similar to the ones you linked. Woot!

Perfect. The 3.5L Montero used the same mounts, regardless of whether it was SOHC or DOHC. Both parts interchange with the 3.5 Sport.

See if those attach to your 3.8 block. If that works, you can transplant the legs from the Max mounts onto the 3.5 block plates.

Just mocked them up. Well I still have the 3s mount on the passenger side but it looks to be a perfect fit. Correct spacing and boss depth on all 4 bolts.

The drivers side fits almost perfect. 3 of the 4 bolt bosses are there but I am missing one of the more important large bolt bosses furthest back on the block. I should still be able to make that work.

Now if I go hybrid I should be good to go. Will try to fit the MM first but at least I have a backup.

Update:

Worked on the Mivec some more this weekend. I was still needing a passenger exhaust manifold, so i hit up the PNP locally and to my amazement a montero sport popped in with a perfect condition manifold. Helped too that everything was 1/2 off in the yard.

I took it home and cleaned up both manifolds as well as grinding off the imperfections. I did this because I believe those casting flaws lead to small cracks that then work their way back into the main casting. It also makes them look better. Anyways cleaning took forever as there was plenty of oil caked on over the years.

I also got to finally install the 04 Sorento oil pan and pickup. The pan fits well except for two of the bolts on the left side pictured below. You can see the top blue marker (located about mid pan on left) where i drilled a new hole for my block. The next hole up doesnt line up as our blocks actually go inward to bold up. No fixing that one. Other than that the new hole worked nicely during the install. Another thing that i overlooked is that the two front holes, where our oil pump meets the pan, were off by just a few mm. This required me to drill out the pan just a little with a dremel. Other than that it went together nicely.



I did have to do some massaging to the dipstick tube off the Sorento to fit. Took a pry bar and a rag to make the bolt hole line up with the head. Then had to use it again at its base, so that the A/C bracket could clear. Works fine for now. Once i attempt to install the MM compressor I will know if any further work is required. Pic of lower pan during install. The pickup looks to sit bout 1/2" above the bottom of the pan. Kind of wish it was closer, but oh well.



Speaking of AC bracket...its going to require some more work to fit this week. Yea its meant for the 3.0 with the oil pickup on the other side, but I really like how well it hugs the block. I haven't been able to get my hands on the appropriate 3.5 accessory plate and corresponding AC bracket, but i think that one will make things stick out a bit more on the drivers side. Im pretty certain I will be able to get this one to fit. Just need to do some more grinding on the back side of the plate. Also fun note. The 3.0 plate is cast steel vs. the cast aluminum on the 3.5's ive seen.

Back to the exhaust. I managed to clean them pretty well and painted them with some really old 1,200 deg manifold paint i had on the shelf. Laid down well, so i let it dry for an hour and put it in our home oven to cure at 400 deg. for 1.5 hours. This was the worst decision of the day. Between the paint curing and the oil still inside the runners my wife nearly passed out in the house. Had to leave all the windows open in 50 deg weather.

Getting closer to completion...

Please tell me you don't cook in the same oven you cured those in.


Coop

Is that the Mitsu oil pickup, or the one from the Sorento?

I'm glad to see I'm not the only one who floods the whole house with fumes. My house stank like fuel for 2 days after the tank in my truck leaked everywhere. Similar weather too.

[quote=""DCIV""]Please tell me you don't cook in the same oven you cured those in.


Coop[/quote]
I did. I dont have extra ovens like some people here. Actually turned out quite well despite smelling bad. No damage to the oven. House smells fine now.
[quote=""Jeff V.""]Is that the Mitsu oil pickup, or the one from the Sorento?

I'm glad to see I'm not the only one who floods the whole house with fumes. My house stank like fuel for 2 days after the tank in my truck leaked everywhere. Similar weather too.[/quote]
Sorento pickup. Yea, wife wasnt happy to be locked into her room upstairs.