DSM 7-Bolt 4G64 swap w/ 4G63 1G DOHC head in a 2G
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Well, wish there where more pictures but my flash card for my camera somehow lost all of the pictures I had for the cam install, that isn't hard though. Prostreetonline has a how to on it. Anyhow some problems I ran into where that the downpipe came up a bit to short about 4"s or so. I will have to get an adaptor or something. The biggest problem I had was that the exhaust cam that was sent to me was a 4G63 EVO VIII cam, well I guess I should have paid more attention to the box because it was on the side. I had just assumed that it was the right one. Well needless to say the engine wouldn't start with it in there. The only thing it would do is back fire. I knew something wasn't right when I was doing the timing belt, normally you have to pull on the cam gear towards each other in order for them to align but I didn't have to do that at all with the exhaust. Anyhow I will get some pictures and when I get the right cam. Hopefully I don't have a problem with any bent valves! The cam could have cause a piston to smack into it. I guess I'll see.
Once I got the engine started, I couldn't let my foot off the clutch because it would bind, and then it would want to stall the car. It turns out that I had the two 36mm bolt torqued to much when I swapped in my 5th gear, causing it to lock into fifth gear. After I torqued them right I could let the clutch out and the problem was fixed.
Its finally running and driving around, here are some pics, I still need to get the exhaust cam installed when it arrives.
I had the car setup in N/A mode the first 500 miles during the brake in period. I used a stock 2G exhaust manifold and a old 14B exhaust housing that had the wheels removed and the shaft plugged. I also used a stock 2G 02 sensor housing. The MAF read the incoming air right before the throttle body so I just put my turbo inlet pip on there with the filter. Pretty spiffy if you ask me.
And here are a few with the turbo installed, I'm still waiting on that exhaust cam though. Note, the blow off valves is disconnected because during my first test drive it blew out the gasket.
I ran into a problem recently at about 300 miles I decided to change the oil again. I had also saw that there was less oil pressure than there was before. Well I cut open the oil filter and found that there was a lot of metal. I knew there was going to be some but not this much. I went through the process of pulling off the oil pan. I took it off and to my surprise I was able to move my crank back and forth about 1/4 a cm. I dropped the crank caps off and took a look at the bearings. Not good, my thrust bearing was ate up pretty good. And there where some score marks on the bearing journals. I determined that there was some oil starvation to the bearings. I then found out that the place I had ordered my bearings from www.slowboyracing.com had more than likely sent me a set of 6-bolt bearings. So I have decided to pull the engine out again just so I could polish the crank again and make sure that I got the right bearings from the dealership this time instead that way I knew I had the right part numbers and the right parts. I also added the extra info on page one at the bottom so that you to can correctly get the right bearings to.
Reflections and reviews of parts:
I thought I would also give my opinion as to how the car felt. There is a lot of talk on some of the message boards about the piston ratio and piston speed. To all those that think this is a problem I disagree. Yes the ratio is considered high and can cause you to lose some power on the top end. But to anyone that thinks that the 2.4L DOHC combo is not awesome your sadly mistaken. In fact once I get everything worked out if your in the local area and would like to go for a ride just let me know. The car pulls great! It make gobs of power, I have never felt anything like it. For the 300 miles I drove it I had it set for a low 10 PSI. I figured that it would be a good setting because I didn't have any tuning done, I was still breaking it in, and I only have the 450cc injectors in there for right now. Well even at 10PSI it was considerably faster than my old 2.0L setup and my 16G at 17 PSI. The T3/T4 would spool up in no time at all, just as fast as the 16G even with the exhaust restriction and stock exhaust cam. If your thinking of doing this swap do it. If you take your time and do it right! It should be more than you hope for. I've even heard that the 2.4 with the 14B will make over 300HP without breaking a sweat. Hopefully with some of the tips and cautions I have shown in the last few pages you won't have a problem. If you have any questions I'm always more than happy to help so feel free. If don't know the answer I will try and find out.
B&M LSD
Some other things I would like to review is the B&M LSD, this is a Phantom grip style LSD. I had installed it while I was doing the build up. It has reduced wheel spin a lot. If you have FWD and your looking for something that will help with that annoying one wheel spin this little $200-300 mod is well worth it especially if you already have the tranny out. It isn't hard to install if you take your time and torque everything down the way it should be. The LSD is still allows me to turn tight corners without squealing a tire, the only thing I noticed is that if there is sand or gravel while you are turning you can feel a slight movement because it will kick the sand out rather than turn the tire (if that makes sense). But it is not a problem once your used to it. In a straight line it works great. Before I used to have a death grip on my steering wheel to keep me from torque steering off the road. Now it just pulls straight and the wheels only loose traction when I push to hard with the right foot.
AWD 5th gear
Another thing I did was swap to a AWD 5th gear. This will give you about an 11% lower RPM than if you had the stock gear set. The AWD gear is .666 the FWD is .741 I believe. It helps out if you drive 80 a lot it lowers the RPMs enough that it still keeps your ECU in closed loop mode this saves gas. It will also mean that you can get more potential top end. It it not boggy and if you have a 2.4L you will have more than enough torque to push it at lower RPMs. It was a direct swap and is real easy to do, you can do it with the transmission in the car. Just remove the passenger tire and the splash shield. Take off the 5th gear cover, take off the 2 36mm bolts and remove the shift fork. Swap on the AWD gear set, install is the reverse of removal. And remember to always torque your bolts to spec.
AWD rear sway bar
I came across a AWD rear sway bar while I was doing the swap. I can say that it did make a difference. The rear end is much more secure and you can take the corners a lot harder. It is a direct swap and you can even sell your stock bar to someone with an RS because stock they do not have them. A comparison between my 97' GST with the stock sway bar and the 95' GST with the AWD sway bar is a noticeable one. If you can find one for under $50-75 it is well worth it!
DSM translator
Just a quick review of the translator. I can't say how much it helps with spool up because I have a completely different setup than I did have. I have heard that it may reduce spool up by 200-300 RPM. I have the MAF in my UICP after the BOV. It is nice to be able to vent the BOV with out a problem and makes the setup easier. With the added benefit of being able to use different injectors and do some small amount of tuning I believe it is well worth the investment. Plus the added benefit of not having to buy an AFC. I can say that it does make the turbo sound a lot louder. If you've ever heard a semi truck turbo spooling up then you know what it sounds like, pure music to my ears. :)
Thats it for now if you have any other questions make sure and check out the Q&A page it may cover your question. Below I'm going to add several helpful sites on the 4G64.
Helpful Links
http://www.carotica.com/4g64/ - This guy did near the same thing as me, there are a lot of part numbers on his site.
http://www.4g64.150m.com/ - This guy has info on a turboing a N/A 4G64
http://www.swordfishgsx.8m.com/photo4.html - This guy did a 2.4L swap but with the 6-bolt
http://www.4g64.com/users/raycer97/ - This site has a lot of part numbers and some how to stuff pertaining to the 4G64
http://www.pinktemple.com/stroker.html - How to put a stroker into a 1G