Hi Eddy and the rest of the Turbo guys

I have a little question here. I understand that an A/T Starion engine 89' can be swapped into the Pajero 89' to use with my Pajero M/T, right? I won't be facing any problem, right? If that is correct, then I'll need to use back my Pajero flywheel, pressure plate and clutch? If I were to use back the Pajero transmission items, will fitting a 240mm clutch plate and pressure plate be better? How different is the stock heavy duty Pajero pressure plate, clutch plate from the 240mm available from TEP? Thanks in advance for the help.

In prep for my upcoming turbo swap, I had a starion pressure plate, clutch and flywheel put into my '89 MT Raider. With the stock carb'd engine, engine response is noticibly slower and engaging the clutch takes more wind out of it's sails than with the smaller NA flywheel. The advantage, I hope, is that the clutch will grab better once I get the turbo swap done.

In short, I didn't experience any problems with the larger flywheel. Just a tradeoff.

HTH

Hey, I am just wondering if someone can explain why to use the Montero oil pump, instead of the Starion pump? I would think that if they are different, than the Starion one would be better since it has more oil to run to the turbo and thru the oil cooler.

Does it not fit with the Montero oil pan?

I am planning on doing this swap very soon since my 95 Talon was just totaled 3 nights ago.

Also I am wondering if anyone knows if it would be possible to use a fuel pump from a 95 Talon turbo for the swap.

Thanks for any input. -Garrett.

The oil pan and pickup are different for the Montero. The pan has to clear the front wheel drive, axle, etc. the oil pump is different to accomodate the pick up.

I would think that if the Talon fuel pump delivers the same or better flow than the SQ or the others that are suggested above, you'd be fine.

If you have a wrecked 2.0 TSI, there are also posts and thoughts about the 2.4L. I'm sure you've read about how the 2.0 head, and related turbo gear can be fitted to the Mitsu 2.4L. That 2.4L block was also used in the pick-up trucks, which were supposed to have the same trannies as the Monteros. So if A=B and B=C...

AFIK, no one has done this yet here. So, we're looking for a first. Try searching, and including user Kevin C for more info.

Hello all

Thanks for the help in getting this bible together. I've got many tips from this. 2 more things that I can't solve to date.

-Under boost, I've got fuel smell coming into the cabin. I've done a throttle body rebuilt and all fuel hoses are clamped tight. I'm scratching my head where the smell is coming from when under boost.

-When the vehicle is fully warmed up and idling, with the a/c compressor off, the idling speed will pulsate around the 1100 - 1200rpm region. Under cold start without the a/c compressor cutting in, it reads about 900rpm. With the a/c compressor on, it about 950 - 1000rpm. I've done the ISC and TPS reset. that didn't work. Where else should I look?

Thanks in advance for the help.

If your TB rebuild included replacing all the injector seals then I'd venture to guess you have a vacuum leak somewhere, if you haven't changed the injector seals I'd check those first, top and bottom. Having been 6 months you've probably already solved this one, but I figgured someone else might run into this issue.


20k since I put the Monty together and its still running reliably on a 205k original short block, though I still had detonation issues on warm days even with the IC. Turns out the fuel map leans out between 10 in/hg. and 0 pressure. It wasn't consistant nor a real serious problem, but at times it was enough to trip the knock sensor and kill the timing curve. My solution was to run a mass airflow sensor out of a first generation Eclipse GSX or GST. They're calibrated a bit differently and cause the Starion ECU to run a bit more on the rich side. I've found the difference to be a loss of about 1.5 mpg, bringing my average mpg down to 15.5.

I never really liked the idea of mounting the IC down behind a vented skid plate, it didn't seem like a location with very good air flow. I had removed my A/C condensor since I turned the A/C compressor into an air compressor, so I inverted the starion's IC and mounted it where the condensor used to be. With that location and using a flex fan the IC sees more than enough air flow to keep things cool with no heat soak from the radiator.

I use the Starion oil pump with a modified pickup tube to fit the Montero sump. I also use the Starion pump on all the 2.6 engines I build turbo or not, they are a better pump.

Most of these swaps use an external fuel pump and your DSM pump is for an in tank setup. They do not have a sealed case.
I use Bosch pumps for these swaps but Starion pump will do too.
I also flair the ends of the Montero fuel line and use the original hose sections from a Starion for the pressure line to the front

Hello all

Here's my setup:

Pic 1

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Pic 8

Might as well chime in on a little something I found incorrect throughout this topic.

You guys have the injector sizes wrong.

After some flow tests the 84-86 injectors actually flow 850cc

In 1987 the went to a primary secondary setup instead of the back and forth setup they had before.
The primary on a 87+ is 550cc, and the secondary is 1025cc.

A decent little upgrade for 87+ cars to remove boost cut, and increase engine response a bit is to add a 1g eclipse turbo MAS.

86 widebodied starions were a ugly duckling of sorts. even with the 10,000k potenthisizer you still cant get past the 15lbs boost cut. It is possible to adapt a 1g mas to the 86 but it requires blocking off some of the unmetered air on the mas. It's a real pain in the butt, but does yeild good results.

I see a lot of people recommending 2,5inch exhaust. Personally, I would go 3. I have had no drawbacks, and dyno numbers seem to prove 3inch is the way to go. The whole key to a turbo setup is to have the backpressure on the exhaust side of the turbo less than the manifold side. if you are vise versa, then you are losing power. I've personally ran both, and must say the 3inch tends to breath a bit better up top. even on a slightly modded car.

there is a faq on starquestclub.com to upgrade the ignitor on a 86, and 87 to the better 88-89 box.

Get rid of the balance shafts to make a more reliable and responsive engine.

As for piston choices. THere are guys putting at least 334rwhp and roughly 387ftlbs of torque to the wheel on stockpistons, so I really dont see the need to go with forged for most applications.

The best aftermarket head is no a clearwater, or alabama, but a MARNEL head cast in spain. They will hold up to overheatings over and over without cracking. They also flow about 30cfm more than a stock head. Your other choice is to get a australian Manga head with a casting of I believe m8 or higher. For na, they also had a kidney based head on the last gen 4g54 made in australia. This would be a good canidate for a high comp na engine.

if you have the money, do yourself a favor and go with a magna mpi converted turbo g54b. You basically get about more hp off a stock starion setup, and 10x the throttle response, efficiency etc... You could easily lay down 300ftlbs of torque to the wheels with a stock starion turbo and mpi.


I saw some mention of a 4g63 and 4g64, they are great engines, but in the engine any turbo dohc setup will not yeild the low end of a starion. The big ol 2.6 is just as capabale as any of the other engines out there. We all know it comes down to money. There is no reliablity issues with a 2.6turbo engine running a marnel head. I've ran an entire drift season with my old 87 conquest with an 18g revving up to 8000rpms on a stock g54b bottom end with bsek. Overheated it many times and it still runs fine

With that being said, the 4g64 would be the next best turbo swap. If you can find a wideblock 4g64 out of a mitsubishi box van, or some early mighty max trucks, they will be wideblock, which uses the same bolt pattern as a starion g54b. After it is all said and done, you will be looking at at least the same chunk of change it would cost to swap in a starion mpi setup.



I've questioned using a na oil pump on a turbo engine, but if you guys are running them without any problems, that solves one of my problems

here are some dyno sheets of modded engines to get you an idea of what mods are gonna give you what powerband on a g54b.

http://www.starquestclub.com/forums/viewtopic.php?t=8890

hi,
I am having trouble finding encouragement to swap in a diesel 4d56t into my 86 montero, so I am considering other options. I found the entire head+top end off a starion including intake throttle body turbo and intercooler - can this be used on the stock montero engine? is this way too much of a pain, or has anyone done this? looks like a bolt on, but I am a bit optimistic. Cheers!