'90 Montero 2UZ VVT-i swap

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Looks like I forgot about this thread 😅

Finished the battery tray.

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Powder coated my new wheels.

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Installed wheels and tires.

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Removed the Montero axle, originally I had wheel adapters for a jeep pattern but a friend that was running the same adapters had one break. So, I lost what little confidence I had in them. The new axle is the M220 or whatever new D44 out of a '21 Wrangler.

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Changed my upper coil buckets to JL Jeep style

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I decided to run the Jeep 5 link as well I have the longer JT low arms and JL upper arms, this is the longest combo. Hope I won't run into issues.

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Had to hog a hole in the frame to access the UCA bolt, trimmed the body mount to clear as well.

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The only real deviation from the stock Jeep links was the panhard rod, I made a custom mount at the axle end. I also had to move the axle side coil buckets inboard a few inches.

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I went through the original wiring, removed all the old 3.0 EFI stuff wire by wire. This was a major task but now it's so much cleaner and will be easier to diagnose issues if needed in the future.

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New 2UZ fuse/relay box and wiring

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The interior wiring is all wrapped up as well, I deleted the old MPI relay system and went with a common Bosch style replacement just for the fuel pump. This will all tuck nicely under the HVAC where the original ECU was located.

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Freshly wrapped front harness.

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Built my new crossmember for the A750, fit is really good but I'll need to rework it. I needed the crossmember to measure accurately for driveshafts but I need a driveshaft to know how much to notch the front edge for clearance at full droop. I added a lot of structure internally so, hopefully it'll be super tough even notched.

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The more I looked at the 4 Runner shifter in the Montero the more I hated it, I started looking into other options. Originally I thought the Montero shifter was going to be too much work to make it shift the A750 and It would be clunky. I looked into a few aftermarket shifters and then took apart a couple Gen 1 and 2 shifters, the Gen 1 shifter is the style I want but there is no way I can fit a linkage shifter under the body now. The Gen 2 cable shifter will work but the challenge there Is that the throw ratio doesn't match the new transmission. I learned the Gen 1 shifter itself will physically install on the Gen 2 cable shifter, this got me motivated to make it work because It will look like it belongs aside from the height.
I cut apart the Gen 2 shifter and shortened the throw of the shift arm to match the ratio of the transmission, this is important because the detents on the in cab shifter need to match the positions in the valve body otherwise ranges won't work or there will be hydraulic bypassing. I also moved the cable position to dead center because that's where the shifter mounts on the Gen 1, hopefully this will allow me to modify a stock center console to cover this mess.


All cleaned and cut apart *did not take a before photo*, I had already measured how much the arm needed to be shortened (9/16").

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Refit the cable mount to test the operation and detent matching.

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Somehow I managed a first time perfect fit and throw!

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Super stoked on this fit up, also forgot to take pictures of the floor mounting bracket. I am aware that the center console mounts to the same holes the mounting bracket is bolted to. I'll try just using longer stock panel screws but I'm prepared to do nutzerts and stainless screws for a clean finish.
 
Wrapping up the small details now, was planning on a start up this weekend but I was short a 90⁰ #10 fitting and I'd like to have my AC lines in place before the radiator goes back in for the last time.

Converted my high pressure fuel line to -6 AN

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Started on my AC lines but I'm short one fitting so, this is what's holding me up now. Allegedly it'll be in today. The cool part is I had a door grommet and it fits the stock hole and the hose perfectly!

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Last PS hose, it's an aftermarket return line and it didn't come with an orifice like the stock one so, I cut it out of the original and installed it in the new hose.

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Cleaned and resealed my blend door with fresh foams.


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In doing this I found two things, the first being that my blend door doesn't work, the plastic holding the cable is broken so the cable doesn't pull. The other is that the blower motor is shot, the brushes were wasted and the commutator is all chewed up. So those need to be replaced.
 
The truck was sitting too low in front after everything had a chance to settle, the V8 is about 250lbs heavier than the Jeep v6. I did some research and found the Diesel JL engine was much heavier than the v6 and the Jeep guys were running the diesel front springs to better carry the weight of a bumper and winch while giving 1" of lift. Luckily, a friend had a set of stock diesel springs just sitting on the shelf. He also had new LCAs and shocks plus a used sway bar, I took everything. I finished the welding on my rear suspension brackets, painted everything and installed the new arms. The plan is still to go adjustable but these are better place holders than what I had before.

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The JL sway bar is tiny which is perfect for just adding a little extra stability while allowing for my full range of travel. I worked on mocking it up since I'm waiting on a hose fitting, It'll sit reverse of the Jeep but the fit is nice and the bar doesn't actually care if it's backwards (up is up)

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The new springs are not only heavier but taller as well, they also are the same left to right unlike the gas springs. It was slightly sketchy to install them in my driveway but I got it done.
The result was better than expected, It's now riding 1/2" higher in the rear and more level side to side than before. It had a slight 1/4" lean because the stock v6 springs are heavier on one side to compensate for the off balance Pentastar v6. The Montero is known for being almost perfectly balanced and the 2UZ compliments that so my future plan was to find another RH front JL spring but this move was better in every way.

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