I picked up the 4M40 eng, trans, case, diff, driveshafts and wiring harness today. Looks like I will swap transfer cases to keep the LHD 4wd shifter and this will also keep the correct speedo gear. Haven't measured the mount position yet, but it looks very close, is further from bellhousing to block line, but engine may sit back closer to firewall to fit 4cyl vs the shorter 6. This could put the transmission mount further back or possibly the bellhousing is longer. Ordered new radiator and figuring out how to mount it, considering front mount universal intercooler vs the stock underhood model since I don't have a scoop. This should leave more room for WVO system valves and filters. Need to drop fuel tank and remove pump, hopefully just use existing dip tube. I'll keep you posted. Was going to blog it all at http://pachamamas.org/monjero
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Did the importer have any 4d56's?

No he did not have any 4D56 motors and he said this was the first mitsubishi diesel that they had ever had. They were in the process of shutting down the warehouse, so that is probably why I got a pretty good deal. Apparently the exchange rate is hurting exporters right now.

When I was swapping the t-case I noticed the shifter on the RHD case overlaps the transmission adapter by abut 2.5"...and the LHD version does not, so I looked at the opening in the floor and it is relatively huge, like 3"wide by 6" long. I remember the shifter being toward the front of the opening, but now I'm a little worried I may have to cut the floor a little or look for a case from a LHD diesel.

My dad was helping and had the idea we could fit the engine and transmission in while the t-case was off. I figured it would not hurt to try, and it may actually be possible if we had taken the rocker cover and crank pulley off, using an engine balancer to tilt it almost straight up and down and lower it in. At least we did not break anything attempting this shortcut, but the motor is back on the floor and I will have time to do lots of little things like check compression and do a leak-down and figure out the wiring mess in the garage after work. Checking the fit will have to wait until next weekend since it gets dark so early. Sorry didn't take many photos yesterday.

Nice project you have going on.. I like the documentation!

Thanks, I want to provide the info since I could not find anything positive out there on this swap other than "if you have the 3.5L you're good to go" Blog updated today at http://pachamamas.org/monjero

Tank out, transmission in, progress on wiring...

I am looking for ideas on alternative A/T transfer cases (3.0L sport anyone?) that have the shifter placement forward of the adapter to avoid cutting the floor and mangling the console. It would be nice to figure it out this week, so I could swap the t-case before putting the motor in. There are Montero Sports a-pleanty at pick-a-part, so I could possibly get one of those cases right away.

Engine went in this morning and everything looks good. There is a 3.0 t-case at a local yard I will check out if they are open tomorrow morning. If not I will just cut the floor. From photos online it looks like the sport 3.0 case has the overhang, but LS does not. Sport has different u-joints, but not sure if regular shafts.

I found a couple 3.0 transaxles on car-part.com and drove 20min to atlas auto and check them out Saturday and they had no overlap. The sport transaxle has one, but it is looks like a different bolt pattern and drive shaft connection. Nice to know they have what's left of a '96 LS to strip parts from.

The motor is bolted in and fits perfect. I cut a 2" extension of the trans shift hole and bolted the shifter in place while the motor was shifted forward 2" and transmission down 2" to cut the hole and get to the top two bellhousing bolts. If this trick is not in the manual, it should be and I wish I had thought of it to get the 3.5l out. Unbolt the motor mounts and pull the motor/trans forward before attempting to undo the top belhousing bolts. Makes it MUCH easier to get to. (you will have the hoist and transmission jack in place for this...) Once the motor mounts were in the shifter has ample clearance and should only be a minor effort to modify the console with some trim and cover the opening with a plate.

Looking at mounting the intercooler where the oil cooler was...in front of the condenser (sans fan). I will need some fancy bending and shaping to get 2" tubing in from the side where the cold air intake and cooling tubes go through. Still not sure if it will fit. Also looking at fabbing brackets to mount top right of motor will probably be easier.

Thinking of using the original air cleaner with AFM in place for now, since I will need to build different mounts for the diesel air cleaner. It looks like the 4M40 intake hose will fit to the turbo from the AFM, but I have not tried it yet.

Decided to just remove the in-tank fuel pump and attach a tube with strainer to the 1" hose section that attaches the pump output to the flange assembly output pipe.

Bought a new section of exhaust (pre-muffler) from Rock Auto Walker p/n 22224 looks like it will bolt right in.

Did not get as much done last weekend as I would have liked, but still good progress. Hope to have it running in a week or two. Will upload photos to blog Thursday cause I got some real work that is due soon.

I've been driving the Monty Diesel since Sunday afternoon. Still some things to complete, but very happy with the results so far. See blog for details. Shopping for biggest tires that will fit stock today. Thanks everyone.

Great write up, i'm looking to replace my 3.5 with a diesel. So if i go 4M40, i'll probably print out your whole blog writeup. I may go with a 4D34 pending some current research but otherwise your write up would still be very usefull to me. keep up the good work.

That is Super nice. Pics please!