LOL! Me? Obsessive? Must be my evil twin. <img src="/forums/images/graemlins/notooth.gif" alt="" />

Yea, I was looking at their stuff last night. Wish I had the manifold and injector setup already 'cause that's perfect for my 'Bird.

Emissions testing here is funky. I'll be fine with the 3.0->3.5L swap. Our testers aren't smart enough to tell a 3 from a 3.5 let alone the years. They're supposed to test based on the year of the engine not the vehicle but what they don't know won't hurt them. <img src="/forums/images/graemlins/smile.gif" alt="" /> The CEL is the biggest potential issue. If it's on for ANY reason or there are even pending codes (codes that don't turn the light on but exist in the computer), they fail the vehicle. They'll actually fail the emissions test if your CEL is on for a ABS issue. Go figure.

Edward

Maybe not solenoid but it's the thing on the far left of the manifold and it bolts down with a little deal that goes into the manifold. The other thing is just a little resistor deal. I can take some pics or post the part numbers, if you buy an engine from a yard or something it will come with these parts most likely.

The throttle bodies are not compatible at all, at least on my '04 engine. had to swap.

Thanks, Toasty. No worries. I have brand new spare everythings except the MAF and the engine is coming complete so I should be good.

What was the deal with the TBs? I know the 3.5 TB is a few mm's larger throat diameter. Is there something else?

Edward

This is where we sit:

Looking at the engine from the front, the coolant temperature switch (left sensor) was relocated on the 3.5L so the wire for the switch needs to be extended. It's a single wire, so not a big deal.

The exhaust manifolds from the 97+ 3.0L are the same as the 3.5L. The exhaust pipe and Y-pipe are not the same. The 3.0L y-pipe has a slightly different angle on the legs and is a inch or two too short on one. The 3.5L pipes are not usable in the pre-99 Sports. The newer pipes have CATs built in and uses O2 sensors installed before the pre-CATs.

Everything on the front - brackets, ps pump, air conditioner, etc. bolt on to the 3.5L from the 3.0L. Timing belt and plastic timing belt covers are different - the 3.5L belt is longer. Since everything was virtually new, we just transplanted almost the entire front of my 3.0L onto the 3.5L engine.

The throttle body from the 3.5L has a completely different configuration for cruise control, different IAC and different TPS. The good news is the 3.0L throttle body is a direct swap. Throat diameter appears to be exactly the same as the 3.0L from my '97.

The motor mounts and motor mount engine brackets are different. The 3.5L mounts and brackets are both longer (taller) than the 3.0L mounts and brackets. How this work, I'm not sure. The block width appears to be the same, so.... In addition, the 3.5L engine brackets are positioned about 1/2" forward of the 3.0L engine brackets. The 3.0L engine brackets are not a direct bolt up to the 3.5L engine. Looks like the solution is to use the 3.0L motor mounts and 3.5L motor mount engine brackets. Snip the bracket off the base plate, cut it down to the correct height and relocate it about 1/2" towards of the rear of the engine. I'll have definite information on this once we drop the engine into the bay for a test fit.

Oil pans are not interchangeable due to the longer stroke of the 3.5L. The pan assemblies are the same height, but the lower section of the 3.5L pan is longer and extends further towards the rear of the engine. This is just a suspicion, but there may be clearance issues with the sub-frame on stock IFS 97-99 Sports. (see the weird motor mount stuff above) The primary issue here is that that extra couple inches sticking back may limits the upward travel room for the track bar and drag link on SAS'd Sports.

Now the sucky parts ... <img src="/forums/images/graemlins/frown.gif" alt="" />

The starter ring on the flywheel is about 1/4" smaller in diameter than the 3.5" flexplate starter ring and the flywheel starter ring sits about 1/4" further away from the back of the block than the flexplate starter ring does.

The 3.0L flywheel bolts to the 3.5L just fine and the height from the block to the face of the flywheel is the same on both the 3.0L and 3.5L. No issues with bolting the clutch and bell housing up.

The starter through 1998 is different than the starter for the 99-2004 and are not interchangeable. We tried my '97 starter on the 2002 3.5L flex plate and it doesn't engage. We then tried the starter from my 2003 3.5L and it works perfectly. The 3.5L starter is PN M379687D.

The bell housing backing plate for the manual transmission is different than the backing plate for the automatic transmission. Both will 'fit', but the manual transmission backing plate leaves a bunch of sizable gaps between the engine, oil pan and plate. There's a tiny gap when using the automatic backing plate behind the flexplate access cover on the driver side of the engine but a very small amount of gray RTV applied before installing the cover will fix that. The gap is REALLY small.


SO, now I'm kinda at a stand still. I have a complete engine ready to drop in and no way to start it.

I would welcome any advice on this!!

Edward

I had to modify the sport motor mounts to fit the Montero frame, swap throttle bodies, move a couple things and swap oil pans. the end. But I was swapping an '04 sport engine into my '99 Montero both 3.5 SOHC.

Yea, the 3.5L automatic to 3.5L automatic vehicle is pretty straight forward. Even the 3.5L automatic to 3.0L automatic vehicle would be pretty simple.

The problem is that the post-mid 90s 3.5L never came with the option to be bolted to a 5-speed manual transmission so there aren't any Mitsubishi parts for a 5-speed V5MT1 to a 3.5L engine.

This is the same problem I had with the V5MT1 5-speed to NP231 that Nathan just breezed through on his t-case conversion. Sigh.

Far as I can tell, I'm stuck having a custom flywheel made. Talked to Standard Flywheels a bit ago. They're supposed to get back to me tomorrow when the machinist is back in. I'm shooting off some more emails to other shops in the meantime.

It's REALLY irritating that the only think holding us up is an almost microscopic difference in the stupid starter ring. <img src="/forums/images/graemlins/angry.gif" alt="" />

What's the difference between the 1999 3.5L oil pan and the 2002/3/4 3.5L oil pan? Does the '99 look like the 3.0L pan? I don't have a way to check since I don't have my '99 3.5L anymore. <img src="/forums/images/graemlins/frown.gif" alt="" />

Edward

Why can you not bolt the flywheel, backplate and starter from the manual onto the 3.5 and bolt these to the bellhousing?

well did a search in [censored] asa and came up with this for the v5m31(manual behind 3.5) starters 1993.07-1993.08 they used part number MD172863, then switched to 1993.09-1997.03 MD313327 THEN 1997.03-1999.11 MD172864

I bet any of those will work for ya my guess is they just kept making little changes to the guts all show 1.2kw and reduction type not sure what they did.

There are two starters for the V6 engines, the difference is the depth of engagement. Granted there are many part numbers but the differences are just detail changes through production.
This is true in 4 cylinder setups as well, the auto and manuals have a different depth.
4 cylinder and 6 cylinder starter housings do not interchange but most of the internals swap over.

well i looked in rockauto under 95 pajero and found Remy DRS3143N has the longer throw out on the starter gear at 17mm and remy DRS3163 is the short throw of 9.0mm

I was looking on remy's website and it shows the N at the end of that part number stands for new starter vs without meaning reman'd hope this helps