So 2 weeks ago I bought a 1994 Mitsubishi Montero SR from some folks who had gotten screwed by the people they bought it from because they misrepresented it's condition. They didn't find out it had issues until it failed emissions for two reasons 1) exhaust emissions (slightly) over limits and 2) fuel system pressurization failure and they couldn't afford to fix it.

It needs work. Probably more work than I realize. It has 164k miles and is 19 years old so some issues are to be expected. For the above emission failure I'm reasonably confident the issue is leaking valve stem seals. Because it seems apparent that the previous owners who had the truck for the last 15 years were not doing any of the routine maintenance (except for oil/belt/spark plugs) and I'm tearing into the engine anyway I'm also replacing other wearable components that were due for replacement in the last 20 years.

I had originally hoped to buy this and have it road-worthy in time for this weekend's Overland Expo up in Flagstaff but unfortunately that's not going to happen. Nevermind the fact that I've been sick for the last 2 days <img src="/forums/images/graemlins/frown.gif" alt="" />.

So far based on research here at 4x4wire and the Expo forums I've identified the following things in need of repair/replacement that I have ordered parts for already:

1. Upper Gasket Kit
2. All Belts
3. Timing Belt Idler Pully
4. Timing Belt Tensioner Pully
5. Timing Belt Tensioner Adjuster
6. Center Crankshaft Bolt
7. Water Pump - I strongly suspect it's the original on there still. Going 3rd part with a lifetime warranty.
8. Lower Air Intake - Not taking any chances on the butterfly valves
9. Alternator - The alternator died (literally) the day before I bought the car. I ordered at 150 amp replacement from www.mralternator.com.
10. New Differential Warning Label - One of the previous owners removed it
11. Steering Column Switches - The left column switch stalk (turn signal/headlight) appears to be bad and causes a buzzer to go off continually and only the left turn signal works without jiggling the stalk around. The warning flashers work just fine so I'm pretty sure it's the stalk.
12. Radiator - The radiator has a small pinhole leak at the top of it. I'll take it to a local shop to have them repair it since I have to take it off anyway as part of the other work I'm going.
13. Radiator Hoses
14. Thermostat
15. Spark Plugs & Plug Wires
16. Fuel System Pressure Leak - I think this is a bad gasket on the fuel tank itself. The gasket is less than $10 so I ordered one and will try that repair first. If it still fails that part of emissions I will have to find a shop that can do an evap system smoke test to find the real culprit.
17. Rear Window Washer Tank - The current tank leaks as I discovered when I filled it up and watched the fluid seep out the bottom of the rear door for the next hour.
18. EGR Valve - Scheduled replacement is 100k miles and I'll already have the engine torn apart to do it.
19. PCV Valve - I'll already have the engine torn apart to do it.
20. Radio - The factory radio is very nice for it's age, but the FM part doesn't appear to work. Plus I kind of like having handsfree bluetooth.
21. Rear Door Weatherstrip - The clips that hold the weatherstrip on the rear door have failed with age and it doesn't seal properly.
22. Various Lights - Some of the interior lights and indicators are burned out.
23. Missing Battery Holder
24. Evaporative Canister - Scheduled replacement is 100k miles.

Regarding the Valve Stem seals, my plan is to buy rebuilt heads from either Clearwater or CHI because I don't own the right tools to do that work and it seems like less work overall to just swap heads. This is the only component I haven't ordered yet cause I'm still undecided if I want to save a few $$$ or save some time.