4G63 swap

[sicSS396]

can anybody give me details on the 4G63 swap? can it be done? i want to do some engine mods, but the 4G64 in the mighty max isn't the most common in the aftermarket. please help!

[poorboyj]

Yeah, I did something similar.

http://www.v8eaters.com/uploaded/jays/turbotruck054.jpg

http://www.v8eaters.com/uploaded/jays/turbotruck140.jpg

Any specific questions about it?

Jay

[CivMoeEJ8]

Originally Posted by poorboyj

Yeah, I did something similar.

http://www.v8eaters.com/uploaded/jays/turbotruck054.jpg

http://www.v8eaters.com/uploaded/jays/turbotruck140.jpg

Any specific questions about it?

Jay

What did you do as far as mounts and tranny?

[poorboyj]

Originally Posted by CivMoeEJ8

What did you do as far as mounts and tranny?

Stock block and tranny, I never pulled them.

Jay

[CivMoeEJ8]

Originally Posted by poorboyj

Stock block and tranny, I never pulled them.

Jay

4G63 Head is a direct bolt on to the 4G64 block!?!?!

[CivMoeEJ8]

That's magnificent! What all did you need to do the swap besides the head? Did you use the 4g63 ECU? What about the engine wiring harness?

[poorboyj]

Originally Posted by CivMoeEJ8

That's magnificent! What all did you need to do the swap besides the head? Did you use the 4g63 ECU? What about the engine wiring harness?

Here's the list I have so far:

Parts:
Turbo exhaust manifold
TD05H turbine housing w/ wastegate
Rebuild turbo - new bearings
Cyclone intake manifold w/ actuators & sensors
Star/Quest FMIC
1G BOV
Turbo oil & water lines
Denso upgraded fuel pump
Turbo manual 450cc injectors
92 turbo ECU, manual, federal
91-94 NON-Turbo throttle body w/ sensors
91-94 CAS
Stock paint valvecover
91-94 engine wire harness
Mitsubishi '94 Galant 2.4L DOHC composite head gasket
Mitsubishi '94 Galant 2.4L DOHC timing belt
Thermostat housing
91-94 fuel rail
1G turbo fuel pressure regulator
Misc gaskets - front case, oil filter housing, oil pickup
Timing belt gears - crank & oil pump
Knock sensor
Timing belt covers
Misc parts - hoses, lines, etc.
Intercooler piping - (2) 2 1/2" 180 degree U-bends
Exhaust piping - (1) flange, (1) 2 1/2" 180, (3) 2 1/2" 90
Turbo outlet flange - downpipe flange
Dynomax muffler - Ultraflow, round, 2 1/2" in, 2 1/2" out
Limited Slip Differential
Galant 2.4 DOHC exhaust cam gears (2) - MD189399

Modifications:
Thermostat housing - 3" interference with firewall Thermostat housing relocation
CAS - 1" interference with firewall Alter firewall for 1" more clearance (BFH)
Balance belt - different tooth pitch Delete balance shaft operation
Timing belt - different width Use DSM timing belt gears & "plate"
Power steering bracket - will not bolt to DSM head Use modified DSM PS bracket to block
Front case - no provision for hydraulic tensioner Use DSM front case
Cyclone intake manifold - throttle body mount on wrong side Block inlet, new flange on other end
Throttle cable - attachment Custom bracket w/ adjustment???
Heater hoses - affect intake manifold fitment Omit heater
Water pump - ~1/4" interference with tensioner arm Clearance
Alternator - won't fit with DSM front case Use DSM alternator
Air conditioning bracket - ~1/4" interference with idler pulley Clearance
Timing belt tensioner arm - ~1/4 interference Clearance
Fuel pressure regulator - interference with throttle body Switch fuel rail inlet & outlet
Brake booster - ~1/2" interference with intake manifold Clearance with BFH
Intake manifold stay - ~1/2" interference with intake manifold Remove
Front motor mount - excess material Cut off excess
Fuel inlet hose - piener Replace with spliced DSM hose
Turbo wastegate actuator - placement & clearance under manifold Drill & tap, use long bolt w/ spacer
Exhaust - 5" clearance between turbine housing and firewall 2 1/2" U-bend, 2 1/2" under truck
Radiator fan - Interference with front mounted water outlet Use electric fan with thermostat (3/8NPT)

[CivMoeEJ8]

Is all of that stuff necessary? I know the head, intake manifold, exhaust manifold, turbo, charge pipes, BOV, engine harness, timing belt and headgasket and maybe ECU would probably be sufficient.

[CivMoeEJ8]

Originally Posted by poorboyj

Here's the list I have so far:

Parts:
...
Cyclone intake manifold w/ actuators & sensors
...

What is the cyclone intake manifold from?

[poorboyj]

Originally Posted by CivMoeEJ8

What is the cyclone intake manifold from?

The cyclone intake manifold is a 3 piece cast intake manifold from some Japanese Mitsubishi cars. It has actuators that control a set of butterflies in the manifold to open a second set of runners. I was hoping, being 3 pieces, I could reverse the top piece, but that wasn’t possible. You could just use a DSM intake manifold, but I got this for about the same price and it included a JDM coil pack and igniter.

Jay

[dinoraver3466]

the 2.0 head also has oil ports .. the 2.4 block needs to be plugged in those spots.. so as far as the firewall.. all that had interferance was the thermostat??? what tranny?.. wide or narrow??? 2.0 auto, or 2.4 manual??? what rearend?? this is my wish l;ist........ 2.4 bottom end.. 4g63t cyclone topend.. rx7 jdm turboII tranny.. starion axels.. stock 410 gears..

Originally Posted by poorboyj

The cyclone intake manifold is a 3 piece cast intake manifold from some Japanese Mitsubishi cars. It has actuators that control a set of butterflies in the manifold to open a second set of runners. I was hoping, being 3 pieces, I could reverse the top piece, but that wasn’t possible. You could just use a DSM intake manifold, but I got this for about the same price and it included a JDM coil pack and igniter.

Jay

[CivMoeEJ8]

Originally Posted by dinoraver3466

the 2.0 head also has oil ports .. the 2.4 block needs to be plugged in those spots.. so as far as the firewall.. all that had interferance was the thermostat??? what tranny?.. wide or narrow??? 2.0 auto, or 2.4 manual??? what rearend?? this is my wish l;ist........ 2.4 bottom end.. 4g63t cyclone topend.. rx7 jdm turboII tranny.. starion axels.. stock 410 gears..

He just bolted a 4g63t head on his 2.4L block...

[CivMoeEJ8]

If you use a dsm manifold the throttle body will be against the firewall....

Originally Posted by poorboyj

The cyclone intake manifold is a 3 piece cast intake manifold from some Japanese Mitsubishi cars. It has actuators that control a set of butterflies in the manifold to open a second set of runners. I was hoping, being 3 pieces, I could reverse the top piece, but that wasn’t possible. You could just use a DSM intake manifold, but I got this for about the same price and it included a JDM coil pack and igniter.

Jay

[dinoraver3466]

then i believe he missed something............i have used 2.0 heads on a 4g64 block without plugging anything...... but every post i read about the 4g63t head says" because its dohc you have to plug some oil ports."

Originally Posted by CivMoeEJ8

He just bolted a 4g63t head on his 2.4L block...

[CivMoeEJ8]

Plug oil ports on the head or the block?

Originally Posted by dinoraver3466

then i believe he missed something............i have used 2.0 heads on a 4g64 block without plugging anything...... but every post i read about the 4g63t head says" because its dohc you have to plug some oil ports."