Mitsubishi Mighty Max

[DCIV]

I hope you are joking. The residue alone from oil and everything would make it so I never would use that for human food again.


Coop

[ChargerX3]

It wasn't that bad. No residue in the oven. Already had some delicious ham yesterday evening. Yum

[ChargerX3]

On a side note.

Jeff I think I might need to look into this intake manifold (2003+ Montero). Looks to do a much better job clearing the valve covers for the TB. Thoughts?

[Monochrome]

That's amazing that you're able to piece all this stuff together and it fits. Just mind blown over that

[ChargerX3]

[quote=""Monochrome""]That's amazing that you're able to piece all this stuff together and it fits. Just mind blown over that[/quote]

Thanks Greg. Oddly its been one of my most enjoyable projects to work on and figure out. I go to sleep most nights trying to fit parts together in my head, or solving why they dont.

[Jeff V.]

Jeff I think I might need to look into this intake manifold (2003+ Montero). Looks to do a much better job clearing the valve covers for the TB. Thoughts?

Remember how I said my intake was going to be taller?

[ChargerX3]

This might be a better option. I do prefer the short ram intake for my mivec. Will help it to breathe and build power in the upper rpm range. The TB looks to sit a tad higher but will require modification to at least it's lower casting to clear my larger valve covers.

[Jeff V.]

The 3.8L MIVEC Pajeros that we never got here (07+) use the same style of intake as the 03-06, and they same style of valve cover as the Eclipse. I think it could work.

[Jeff V.]

Pajero MIVEC.





Is the unpainted cover shorter than the red one? That might explain how it fits.

[ChargerX3]

Nice, that picture really helps put it into perspective. I could make that work. The unpainted cover belongs on the passenger side anyways. That will then allow me to have my timing cover mounting position on the passenger head.

[Jeff V.]

Time for the secret triple diamond decoder ring. I don't feel like typing out the full names every time I want to describe something.

K99 = 3.5L Montero Sport
V77 = 3.8L full size Montero
V97 = 3.8L MIVEC full size Pajero
DK4 = 3.8L MIVEC Eclipse


So, due to the weird shapes of both intakes, it's tough to say just how much taller the V77 part is. There's a bunch of mounting bosses and vaccuum crap on top of the K99 intake that could potentially be eliminated, reducing the total height. Overall, the V77 intake is between 5/8" and 1 1/8" taller, if you eliminate the MDP sensor.

More significantly, the V77 intake moves the throttle body outward by a considerable amount. There's a flange underneath the throttle body that connects to the EGR pipe and a mounting bracket that attaches to the passenger side cylinder head. This puts the bottom of the V77 throttle body flange very close to the top of the valve cover. Since the V77 and K99 have similar steel valve covers, this isn't a problem.





However, the V97 uses aluminum covers very similar to the DK4 Eclipse. I'm skeptical that the V77 throttle body flange could be made to clear the DK4 valve covers. Good luck finding anyone selling a standalone V97 intake manifold who is also willing to ship it to the US. I had a tough time finding a V77 intake, with all the related parts, without buying a whole motor. Those were sold in the US to start with.

On the other hand, I think the K99 intake is going to be a restriction on a 3.8L engine. If you look at either the V77 or DK4 intake manifolds, or even the manifold on the 3.8L non-MIVEC Galant, they use huge intake plenums and runners. The V77 intake even has a vacuum actuated butterfly system reminiscent of the variable intake on the 3000GT SL.

[ChargerX3]

Thanks for checking those dimensions. Yea the v77w does stick out further over the valve cover which I need. Looks to sit quite a bit higher like you said too. I might install my motor with the k99w attached so I can verify hood clearance. If that won't fit then it won't matter if I get a v77w like yours. I would also hack off the lower egr stuff. Won't need it.

I still need to verify how the 95 SR system actuates as its similar in design to the v77 but sits much lower and contours the dohc heads. Might be a good fit.

I think the k99's shortcoming is going to be it's set up for low end torque and not high revs like my motor. The runners are the same size between it and the dk4 where they tie into the lower manifold. Yea plenum is bigger and yes the runners start off a bit bigger but inches later they taper down to the same size as any other 6g motor. I expect there to be so e gains as that should help to charge the air but it may not be much.

[ChargerX3]

Worked on the motor some more this weekend. Moved the valve covers around and got my 95 SR intake to fit. Only problem is the lower intake manifold wont match up (its DOHC like the 3s), so i then tried to use my Monti sport lower (it has circle shaped runners too). They lined up, but are smaller in size and the two end bolts for each side do not line up, leaving only 5 intake bolts out of 7 to fasten it. Not super sold on that solution at the moment.



I then decided to try my monti sport intake again. Just had to trim up the drivers side casting to fit around the red valve cover. The SR TB sits firmly on the cast cover. Had to rotate the IAC 180 deg. I may need to shop around for a low profile alternative TB.



Here is the other side. Fits pretty well. Also spent the rest of the day trimming up the AC bracket to fit perfectly. Had to cut out a couple areas. Filled the EGR return bolt with JB weld and then refitted it too (not pictured).




Finally switched over the CAS gear. Hopefully Jeff is correct in thinking this new one will work with our 3s ecu. Anyways upon tightening the bolt I managed to hear it....snap. Yea, broke a bolt off in the cam gear! Pissed off, I tried to pull out the head with my finger tips. Huh, no go. Put the wrench on and started to back it out. Came out like this. I got sooooooo lucky.

[vr4]

Wow. Wish I got that lucky today.

Doing a head on an ecotec. Forgot an exhaust bolt had broken on removal "eh no big deal. We pull them all the time". Well this fucker wasn't having it. After reassembling and timing the engine finally gave up on extracting and had the head off 12 minutes later.

4 hours later we finally got it out and helicoiled.

[ChargerX3]

I feel your pain. I was surprised at how easily it wanted to break.

[Jeff V.]

So that's the Max AC bracket you're using now? Have you looked at interference with the motor mount plate?

[ChargerX3]

Its actually a 3.0L Monti sport AC bracket and front accessories. The SR mount lines up with no interference.

[Jeff V.]

You should chime in here. There's a decent 3.8 discussion that came back to life.

http://forum.expeditionportal.com/threa ... Swap/page3

[ChargerX3]

I went ahead and chimed in. Have some more updates for here, but i might wait until i install the motor this weekend....hopefully.

[vr4]

I'm about to crush my 91 v6 auto Montero. Anyone want anything?