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Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: FrankR] #1045989 07/17/12 12:51 AM
Joined: Jul 2003
Posts: 850
ES_97Sport Offline OP
Rock Warrior
*****
Thanks, guys!

Talked to Patrick at Griffin, finally. First, he thought I was nuts running the stock radiator. <img src="/forums/images/graemlins/smile.gif" alt="" /> Had trouble figuring out how that ever worked. Anyway, a new radiator from them is in the works. 3" core, with dual 1.25" tubes.

The ECU just isn't completely happy. As far as I can tell the 3.0L used 210cc injectors and the 3.5L used 275cc injectors. Or there in abouts.

The 3.0L ECU fuel trims are in the negative rage far enough that it's having trouble scaling back further on steep descents when you let off the gas. Enough that I can barely hear what's happening in the exhaust - but the issue is there.

Part of my ECU problem is the heat, of course. IAT temps are way up there because of ambient temps. The engine is running too warm because of the cooling issue. But, the timing for the 3.0L is just a tad too aggressive for the 3.5L over about 2800 RPM. Seems to be very similar to timing a Chevy small block 350 vs. a Pontiac 350.

So, I'm looking for a '99 3.5L Fed ECU, checking into Tactrix Openport and EvoScan and looking at MegaSquirt and other piggy-backs.

Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: ES_97Sport] #1045990 07/22/12 09:53 PM
Joined: Jul 2003
Posts: 850
ES_97Sport Offline OP
Rock Warrior
*****
Quote
... Anyway, a new radiator from them is in the works. 3" core, with dual 1.25" tubes. ....


Woohoo! My new PSC steering box is in! <img src="/forums/images/graemlins/smile.gif" alt="" /> Wow!! What a difference!!! The original box was pretty thrashed. Steers like my little '97 now.

Thanks, Frank. That was a good suggestion. Unfortunately, during the installation we repositioned the engine. The stock fan shroud and fan doesn't line up with each other anymore. <img src="/forums/images/graemlins/frown.gif" alt="" /> I agree that it's unlikely to be flow related. I also don't think it's entirely radiator size - since the 3.0L and 3.5L use the exact same radiator. It looks to me like the timing maps are too aggressive for a 3.5L on a vehicle this heavy at this altitude. Running hot is an effect not a cause - the stock radiator isn't capable of efficiently dealing with the result.

I spoke to Griffin again after Patrick confirmed all the information I'd given him with their engineer. I misquoted Patrick. The new radiator is actually a 2 3/4" core with 3" tanks and dual 1.25" tubes. There's some hangup on the stock fan shroud mounts that I don't understand. I guess I'll find out when it shows up. I'm supposed to contact them just before the 1st of Aug for an update and/or ship date.

I replaced both O2 sensors. I was concerned that with replacing the engine, most of the front exhaust and going through a quart of oil a month the existing O2 sensor(s) weren't giving correct readings. I dropped my spares in and that actually helped a good bit. Everything has stabilized and at least now runs consistently.

My Innovate wideband O2 setup arrived a couple days ago. I didn't bother getting a gauge since I only wanted this to feed into my OBD-II/CAN diagnostic/logging software. I'm off to the shop this week to get an idea of what to do with the exhaust and get an O2 bung welded in. Then it'll be time to wire it up.

Ran across this "Recommended Innovate LC-1 Installation" and thought it might be of some interest. For the '97-'99 Sport the closest approximation is the DSM 2G (ECU wiring/sensor stuff).

I found and have a Fed '99 3.5L ECU (MD357516) on the way and I have an email in to Dynotronics. They supposedly can do stock Mitsu ECU flashing and tuning. I'm hoping they can at the least flash a '97 3.0L ECU with the maps and injector size from the '99 3.5L ECU. That would be a start. The only drawback here is it's almost as expensive as a piggy-back unit or a Megasquirt (MS).

I managed to pull the ROM using the Openport and Tactrix's ECUFlash software on my '03 and use EvoScan to log on my '97 but that's as far as I've gotten. The primary two issues is having to build or have built a definition file for each new ROM version and virtually no information on the '97-'99 non DSM ECUs. This is going to be a long, LONG road if I choose to continue pursuing it. <img src="/forums/images/graemlins/frown.gif" alt="" /> Either way, in the meantime I'm putting together a list of Sport ECUs, board and chip numbers (with pictures where available) of the ECUs I currently have. I'll submit everything to the EVOScan/Openport/Tactrix bunch and see what comes of it.

A full ECU replacement of the OEM ECU is out - my vehicles must pass the CO emissions tests which include the OBD-II port read. As of this date, there are no aftermarket ECU replacements - including Greddy, Haltech, Megasquirt, and AEM - that have OBD-II/CAN support. There's almost no chance it'll pass emissions now so replugging the stock ECU for the test and then switching back isn't an option.

A parallel ECU installation is probably possible but for this application seems overly complicated. Trying to figure out how to get the OEM ECU to NOT pop trouble codes with the tps/maf, injector, timing, O2 input/outputs disconnected is very difficult. All the MS posts recommend either a full ECU replacement or piggy-back - not a parallel install.

That leaves installing a piggy-back unit.

Of all the units out there, the AEM F/IC 6 and 8 appear to be the current hotness. Either will theoretically do what I need it to do - straighten out the injector size discrepancy and get the fuel trims back to 'normal' and decrease the timing where needed. It also comes with MAP built in - which is nice since the 3.0/3.5L MAP values aren't available via OBD. It won't USE a wideband o2 sensor for tuning, but it will accept nb/wb input and log the information - critical information for tuning a piggy-back unit. One drawback is that they're expensive. In the $375 range for the 6 and $575 range for the 8 - 'universal' models. <img src="/forums/images/graemlins/frown.gif" alt="" /> An extension harness so you don't have to chop the factory harness is around $130 and an Innovate LC-1 runs about $150 w/o gauge.

Mitsu owners with a frequency based MAF - '97-'99 Montero and Montero Sport vehicles, for sure - must use the F/IC 8 if they want to hook into the MAF. The F/IC makes adjustments based on load so there must be a 'load' input - either MAP, MAF or TPS. I don't know if it's a requirement to patch into the MAF for what I would want to do or if the MAF is just a better choice of signals. If it's possible to ignore the MAF and use MAP/TPS and have everything work just as well, then the 6 might work fine.

Using a Megasquirt in piggy-back configuration is possible but - AFAIKT - just as (or more) expensive. The only positive is - again AFAIKT - if you buy the MS3 with gee-gaws, you can get sequential injection. Whether you can advance timing in a piggy-back configuration (the F/IC only retards) is unknown. A nice perk would be knock sensing/control (which the MS can have) but I can't find any information on whether it would work in piggy-back mode. A very large portion of MS features will not work in piggy-back mode - only parallel mode.

All support - and I mean ALL - is from the 'open source' community. If you don't already know your way around OEM and aftermarket electronic FI and ignition systems well, do not expect any support on the forums. As the product documentation states - not for NOOBS, the electrically, mechanically, reading, comprehension impaired or challenged.

Anyway, for a MS3 with MS3X completely assembled and 12' patch cables the starting cost is close to $800. IMO, this is a LOT of money just to control fuel and ignition. <img src="/forums/images/graemlins/frown.gif" alt="" /> If you buy the kit then you can knock off about $200-250.

Megasquirt comparison page

AEM F/IC 6 and 8 comparison page

I loaded and looked at the AEM F/IC software a little on Friday. Looks pretty straight forward and is reasonably intuitive. I think it's easier to navigate than EVOScan - whether it as easy to tune with is unknown. I'll dl the MS software and poke around it this weekend. I don't expect it to be much different than AEM's AEMPro software.

How to MegaSquirt your Chrysler, Dodge, or Mitsubishi 3.0 SOHC (kinda outdated)

Knock module for MS3 (beta test)

Megasquirt KnocksenseMS


Edward

Last edited by ES_97Sport; 07/23/12 05:43 AM.

'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: ES_97Sport] #1045991 07/23/12 03:10 AM
Joined: Feb 2004
Posts: 10,238
FrankR Offline
Web Wheeler
****
I used a 3.0L block from a Diamante so I could use the knock sensor that bolts onto the plate between the L/R cylinder banks, then installed the KnockSense unit with my MS2v.3. I have no idea if it works, since I've never seen the LED light up - but then, I'm not running a lot of boost and I have the MS set to retard spark more as boost increases. I've thought about tinkering with it to see if I can find a knock, but for me, some things are better left alone when they're working properly. I do have a habit of getting too far over the edge sometimes. <img src="/forums/images/graemlins/scared.gif" alt="" />

Frank


'89 [color:"white"]G-Raider[color:"white"] [color:"black"]Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 172k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, Lifeline AGM, Rust-Oleum
Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: FrankR] #1045992 07/24/12 12:18 AM
Joined: Jul 2003
Posts: 850
ES_97Sport Offline OP
Rock Warrior
*****
Quote
... I've thought about tinkering with it to see if I can find a knock, but for me, some things are better left alone when they're working properly. I do have a habit of getting too far over the edge sometimes. ....


I hear that! <img src="/forums/images/graemlins/lol.gif" alt="" />

Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: ES_97Sport] #1045993 07/26/12 09:15 PM
Joined: Jul 2003
Posts: 850
ES_97Sport Offline OP
Rock Warrior
*****
Ok. This is where I'm at so far ...

Tactrix Openport EcuFlash and MMCFlash aren't capable of flashing '97 Montero Sport ECMs. So, that's out. I have an email out to Dynotronics with pictures of the '99 and '97 ECM to see if they can do it. Nothing back yet.

I'm STILL trying to get some definitive information on whether AEM's piggy-back F/IC will allow you to drop timing and fuel on a naturally aspirated vehicle. I'm starting to think a parallel install of a Megasquirt isn't such a bad idea. <img src="/forums/images/graemlins/confused.gif" alt="" />

I picked up a '99 3.5L ECM this week and pulled the pin-outs for the '99 3.0/3.5 and '97 3.0 from the Mitsubishi service manuals. (see PDFs at the bottom of the paged linked to down below)

I've went through (several times) both the '97 ECM and '99 PCM pin-out diagrams and the only thing that differs in between the two is:

1) '99 automatic transmission PCM has a pin for neutral/park & drive.

2) '97 manual transmission ECM has a pin for ABS.

I know I can ignore #2 because neither of my '97s have now or ever had ABS, so it obviously can't be doing anything.

Does ANYONE know what #1 is for?? Even the techs can't explain to me what that's supposed to do and whether it can trigger CEL.

According to the service manuals, there's no difference in sensors (voltage, ohms, etc.), both have all the same input/outputs - so other than the above there's nothing added or missing between the units.

My BIG question is:

If I were to wire all the pins from my '97 harness into the locations specified by the manual for the '99 PCM, will it work??? There seem to be a LOT more pins on the connectors for both years than there are pin-out specifications in the manuals.

My idea currently is to wire the new PCM into my '97 harness. Prefereably without hacking the original harness. I have an email with pictures of both unit's plugs out to Boomslang. I'm reasonably sure that they have/or can get plugs for the '97, but the '99 may be a different issue. I guess I'll find out. If they have plugs they're happy to wire up a one end of a short conversion harness to go from one to the other and then I can do the other end based on the documentation I have.

Otherwise, I'm going to be looking for a '99 harness I can scavenge the PCM plugs off of, hack the plugs off my existing '97 harness and wire the new plugs in. That's not a plan I'm happy with if I have no idea if it'll even work. <img src="/forums/images/graemlins/frown.gif" alt="" />

Any insight would definitely be appreciated. I know a lot of you guys have done a lot more with automotive wiring than I have.

'97-'99 Montero Sport ECM/PCM Info

BTW, if any of the Sport people here are interested, I'm trying to document the '97-'99 ECM/PCMs - P/Ns, production years, pin-outs, images. I'd welcome the Mitsubishi service manual pin-outs for '98 if anyone has them along with clear pictures (top, plugs, and PCB) of any of the units I'm missing.

Edit:

WOOHOOO! Boomslang just emailed back. They have plugs and can make harnesses for both the '97 green 4 plug ECM ($125) and the '99 black 4 plug PCM. I'm waiting for whether they'll wire a cross-over '97 female green -> '99 male black harness or if I have to buy a flying lead and do the other end myself.

Edward

Last edited by ES_97Sport; 07/26/12 10:01 PM.

'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: ES_97Sport] #1045994 07/27/12 12:01 AM
Joined: Sep 2006
Posts: 2,712
OldColt Offline
Roll Me Over
*****
The 97 sockets are easy to get, they are Tyco 70/40 series, I have bought them to make Megasquirt adapters.
i read a few years back what the 99 series plugs were, I would need to rummage through my notes. Someone was making adapter harnesses a few years back, I have not kept up to date on this.
P,R,N connector is for idle up. The ECU will not care if that is open.

Is that $125 for the socket or the full adapter?


Cheers, Charlie
If It ain't broke, Modify it!
87 Montero turbo Converted back in Spring1989
95 Montero SR 3.8 DOHC Only one?
93 Pajero 3 door 6G75 Mivec with paddle shifted 5 speed
Then a Gen2 SR with full coil independent suspension.
Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: OldColt] #1045995 07/27/12 12:43 AM
Joined: Jul 2003
Posts: 850
ES_97Sport Offline OP
Rock Warrior
*****
Quote
The 97 sockets are easy to get, they are Tyco 70/40 series, I have bought them to make Megasquirt adapters.
i read a few years back what the 99 series plugs were, I would need to rummage through my notes. Someone was making adapter harnesses a few years back, I have not kept up to date on this.
P,R,N connector is for idle up. The ECU will not care if that is open.

Is that $125 for the socket or the full adapter?


That's good to know! If you run across the black plug info, let me know.

WOOHOOO! Again! <img src="/forums/images/graemlins/smile.gif" alt="" /> Boomslang just wrote back and said they'd be happy to do the entire '97->'99 harness - they just need a pin-out.

Boomslang, "We have found that Mitsubishi doesn't always list the complete pinout of their ECUs in a singular place in their service manuals."

This wasn't real encouraging, though. <img src="/forums/images/graemlins/frown.gif" alt="" /> I don't even know where to start - other than to read through the entire service manual. <img src="/forums/images/graemlins/barf.gif" alt="" />

$125 for the complete 'standard' female green plug to male green plug harness. This is just a pre-assembled extension harness.

$80 for a 'flying lead' (semi-assembled) harness. Four green+pins (in a baggie) and four black, pined and wired.

Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: OldColt] #1045996 07/27/12 09:46 PM
Joined: Jul 2003
Posts: 850
ES_97Sport Offline OP
Rock Warrior
*****
Quote
... P,R,N connector is for idle up. The ECU will not care if that is open. ....


Correction on my previous post. Both the auto '97 and '99 have this pin-out.

I was looking at the '99 manual again earlier this morning at the shop. It states that if a fault is detected it will trigger an error. Doesn't say much of anything else.

So, if I'm reading the manual correctly - in P/N the PCM is expecting a 0-3v signal, and in D/2/L/R it's expecting a 8-14v signal?

Sorry if this is a stupid question. Not my strong suit.

Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: ES_97Sport] #1045997 07/27/12 09:48 PM
Joined: Jul 2003
Posts: 850
ES_97Sport Offline OP
Rock Warrior
*****
Guys,

Putting spreadsheet for Boomslang for the new harness. I have two pin-outs on the '99 Sport PCM that do not show up in the '97 ECM doc.

Condenser fan relay (pin 18)
A/C switch 2 (pin 61)

Are these inputs or outputs???

(description is in the PDF linked to below)

It's not the following. These match up between '99/'97 ECM/PCM.
A/C compressor clutch relay
A/C switch

1999 Montero Sport 3.0L/3.5L PCM Pin-Out


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: Transplant 6G74 engine into a 6G72 Montero Sport? [Re: ES_97Sport] #1045998 08/02/12 12:37 AM
Joined: Jul 2003
Posts: 850
ES_97Sport Offline OP
Rock Warrior
*****
Quote
...
Condenser fan relay (pin 18)
A/C switch 2 (pin 61) ....


Got it. These two are changes between the ECM and PCM.

Condenser fan relay (PCM input)
B+ votage applied to pin 18 from condenser fan motor relay; when PCM switches on its power transistor, condenser fan motor relay coil is energized, causing current to flow in the circuit

A/C Switch 2 (PCM input)
B+ (A/C load high) to V<=1v (A/C load low); PCM receives signal from automatic compressor-ECU (pin 3) and determines idle-up speed according to high/low air conditioning load

Waiting for my '99 service manuals to clarify if this is valid for '99 or only '00-'04. Getting tired of borrowing the shop's set and sitting in their waiting room for hours going through one page at a time.:)

Still have to figure out what if any of the A/T stuff is present in the PCM and what to do about that. I have to wait until vol2 shows up. Dealership is missing that one so I haven't been able to go through the wiring diagrams - they all live in vol2.

If I never see another service manual again after this it'll be too soon. <img src="/forums/images/graemlins/shiner.gif" alt="" />

For thems who care, DIYAutoTune.com makes an ECM break-out-box. Their list isn't teribly accurate so they probably have a PCM box, too. Anyway, I thought it was interesting.

DIYAutoTune.com DIYBOB

Griffin is supposed to ship my new radiator on Monday and I'm picking up a new A/C condenser this weekend so, ... one step further along.

Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
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