Swapping 02 sport 3.5 into 99 Montero

PA_JERO

Adventurer
Yes, toasty did this with a low mile 04 montero sport 3.5. You will need to swap throttle body, oil pan from your current motor to the new one. Other than that it just goes in. If the 02 sport uses the new style motor mounts (round), then you will need to use your old mounts or just have some new ones on stand by that are for a 99 montero.
 

Toasty

Looking for that thing i just had in my hand...
I Modified the round mounts to work because they were new and had more rubber surface area. (and I'm frugal) I think we also extended a temp sensor wire to reach it's new location on the Sport motor (like 3" away) and the Sport motor might not be plumbed for your oil cooler (because Sports are built to be cheaper) so you'll need the adapter for $26 from Earl's.
 

BOPOH

Explorer
You can reuse your oil adapter, but you have to take off harmonic balancer which requires doing a timing belt. Overall the entire swap is easy, i've done it HERE
 

PA_JERO

Adventurer
Question, why do you have to do a timing belt when you remove a harmonic balancer? I can remove mine with no timing job needed.
 

BEG

Adventurer
Question, why do you have to do a timing belt when you remove a harmonic balancer? I can remove mine with no timing job needed.

Agreed. The HB can be removed without removing the crank timing gear.
 

BOPOH

Explorer
In theory yes, i had two that didn't want to separate. If yours is easy to remove without moving the sprocket, you are golden. I'm just suggesting to do a timing belt while the engine is out, it's so much easier
 

Toasty

Looking for that thing i just had in my hand...
I think it's a fuel mapping deal, and we're talking 1-2hp. Interestingly, in some less emissions choked out markets the SOHC 3.5 makes 219HP. In theory the ECU in the late model trucks would "relearn" it's fuel trim after some time if one were to lets say make some adjustments.
 

PirateMcGee

Expedition Leader
I think it's a fuel mapping deal, and we're talking 1-2hp. Interestingly, in some less emissions choked out markets the SOHC 3.5 makes 219HP. In theory the ECU in the late model trucks would "relearn" it's fuel trim after some time if one were to lets say make some adjustments.

That's right, for some reason I was thinking the Sport made 190hp instead of 198.
 

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