Project Zero G Forums

I'm thinking a retro interpretation of the pajero evo, a rally raid truck!
rally raid time! 2.4L 9:5:1 comp


Crank in, all 2.4L of this big girl wears a full girdle.


The laboratory


Doing a complete overhaul of everything to get it abuse worthy. There's something like 10+ yrs of deferred maintenance lurking under this thing and a tired trans that howels like a WRC gearbox. haha, poor little truck's had the heck beat out of it off road for many years.




Found a factory mechanical LSD!


LSD trip FTW!

packages with car stuff yea!!


Poppin in the bouncy bits!


aaand this is why you don't get in a hurry.... bent oil control ring FTMFL...


Getting it ready 4 paint


Oh boy, mail santa brought me a box!


It's baaack...


and better than evar!


Next comes this


my cats must hate me.


In its former life


It's been slow going lately, were in the middle of moving the shop to a bigger building so .....
Artsy piston shot.


Cleaned the head, no more dirty thoughts....


Test fit

Getting the factory thermostat location cleaned up for a block off plate


Measuring to drill for 2nd coolant hole at the rear of the head.


Treasure located, time to dig


Start with a little bit, there's not a ton of room for error. EGR passage on one side and valve dome wall on the other
and its gotta line up with the passage on the block


First small hole drilled


drilling second larger hole after confirming correct location


Done, yay!


Lines up nicely


Notice front of RWD head gasket has no coolant passage holes


The maddness behind this is, because I'm moving the thermostat housing to the front of the head I need to improve coolant flow through the rear so coolant doesnt sit there stagnant and steam. I accomplish this by closing off the ports in the front and opening them up in the rear of the head therby forcing the coolant to flow up through the back of the head from the block and to the front exiting via the newly located thermostat housing.

Moving into the head with the boroscope.



Shavings from drilling are on the floor of the coolant passage which is actually the celing as the head is upsidedown right now,
the big circular structure ahead with the casting line in it is the outer jacket of cylinder #4's valve dome.



Were on the inside of the coolant passage in the head looking through the hole I just drilled,
yes that is my eye ball pressed against the outside bottom of the head looking back inside.


Helping the epoxy paint on the moddified headlight bezels to dry


Stir in some moddified BMW 5 series projector buckets


With a nice press in fit.


Add some clean epoxy adhesive action


compared to old sealed beam


retro modern projectors!! and they retain factory aiming ability. I might give 'em halos, depends on how fast and furious I feel later.


rarrr!

New injectors yaay!


Mitsubishi loves california so much that they included a model of it with every 4G! haha


MOre to follow

I like this any updates?

Some progress

Very cool!

Just joined the site, what transmission do you have in the Montero?

Wayne

Running the km145 and mitsu transfer case.

I love this thing. Any updates?

Picture dump

for these pan mods did you lengthen the oil sump pick up towards the back?
Im making the same style pan for my swap, and im trying to get it all worked out before I bolt it in the monty.


If so got any more pictures of the sump/ also with your new pan design in the pajero?

Also is that a jay racing waterneck that fits?

Any more updates?

Ok so just curious one of your other pic showed the factory pistons in the engine so will the 8v factory piston work with the dohc I am hoping they will any info would be great I am not wanting to turbo my 4g64 engine just wanting my Montero to be more reliable than the g54 and the more compression would be better oh and Alsom build

Wow I've been gone from zeroG for a while. I saw I got some PM's and other questions, I will post some progress updates and pics tonight. Long story short though wound up at 27psi of boost pressure with pre turbo meth injection and grenaded the transmission one transmission in six months and another fresh rebuilt one in four months haha, it was awesome...

....

Bulletupfl wrote:Ok so just curious one of your other pic showed the factory pistons in the engine so will the 8v factory piston work with the dohc I am hoping they will any info would be great I am not wanting to turbo my 4g64 engine just wanting my Montero to be more reliable than the g54 and the more compression would be better oh and Alsom build

Yes the dished pistons will work but will stick you in a reasonably high comp range, you will have to use premium fuel. I changed out those pistons for a set from CP forged pistons at 9:1static comp that were .40 over factory so I could run higher boost. I'll be ditching the dsmlink for an evo 9 ecu and I'll be going to a billhousing and a 4l60e transmission with stand alone tcu.

4G63 2.5 turbo Pajero test: http://youtu.be/q3L32JlPM0A