Project: 89 240sx Coupe w/ 4G63

Somnambulist · Post by **Somnambulist** » Thu Oct 29, 2009 1:45 am

Damn long ways away.

shroder15 · Post by **shroder15** » Fri Oct 30, 2009 1:45 pm

The trans on the chaser/soarer is longer BECAUSE it has a different rear housing. It not the entire trans...similiar to the th350 transmissions. But, along with the end being longer, you need the longer internal shifter selector rod...or you can modify it to work. But there are 2 different ends...you dont have to buy that trans if you can get your hands on the back portions. Check it out on the website I posted...2jzswap.com and look at the 240sx portion. Same issue as us!

DoubleJ · Post by **DoubleJ** » Fri Jun 11, 2010 11:53 pm

It has been awhile since I have posted. I got an awd for the winter and it didnt even snow!!! But I am still working on the project. Slowly but surely! The date I am shooting for is August 1st!

I have been through 3 other DSMs since i last posted lol. But now focusing on the 240.

The newly planned mod list:

780cc Injectors
Evo 16g
Methanol
16 gal Fuel Cell
A1000 Fuel Pump ($150 bucks!!)
A1000 regulator
stock 7.8:1 6 bolt motor
chip (until the car is running for awhile then goin with ECMtune)
Evo 8 Intake Manifold
Polyurethane Motor Mounts

Right now I just deleted the balance shafts and i am putting the motor back together etc

DoubleJ · Post by **DoubleJ** » Sat Jun 12, 2010 12:02 am

Welded and resurfaced EVO 8 Intake manifold:

kyle · Post by **kyle** » Sun Jun 20, 2010 7:46 pm

You're in Seattle? I just started a swap like this about a week ago. Im still piecing together an engine and tranny combo. My only concern is that I just got done with my RHD swap, so i'm afraid the 6 bolt will have turbo clearance issues with the brake booster/master or the steering column. Im sure its nothing some custom fab work wouldnt take care of though.

Yours is lookin good so far!

DoubleJ · Post by **DoubleJ** » Mon Jun 21, 2010 1:46 am

kyle wrote:You're in Seattle? I just started a swap like this about a week ago. Im still piecing together an engine and tranny combo. My only concern is that I just got done with my RHD swap, so i'm afraid the 6 bolt will have turbo clearance issues with the brake booster/master or the steering column. Im sure its nothing some custom fab work wouldnt take care of though.

Yours is lookin good so far!

Thanks. So you are going a 240sx? Where are u located?

kyle · Post by **kyle** » Mon Jun 21, 2010 3:01 am

Im in Lakewood. I've been into 240s for quite awhile. I started building my RHD shell and then was brainstorming engines. I had a 240 with an SR20 (it just got stolen a week ago) and I was just going to swap that into the RHD chassis. Now thats its gone i've decided just to go 4g instead. I think it will work out pretty well.

DoubleJ · Post by **DoubleJ** » Mon Jun 21, 2010 7:34 pm

kyle wrote:Im in Lakewood. I've been into 240s for quite awhile. I started building my RHD shell and then was brainstorming engines. I had a 240 with an SR20 (it just got stolen a week ago) and I was just going to swap that into the RHD chassis. Now thats its gone i've decided just to go 4g instead. I think it will work out pretty well.

Pretty coo.. we will have to crash the NWN meet next year huh lol. With the mighty max motor mounts I can directly mount the motor in. But I need to move it farther towards the firewall.

Im gettin pretty close to gettin the motor all bolted down. Should have a good amount of picts in the next 2 weeks. Im also working on mounting my fuel cell and battery. Deciding how much of the trunk I want to cut to mount em.

DoubleJ · Post by **DoubleJ** » Mon Jun 28, 2010 2:17 am

Update.... (most people have high speed internet these days so I posted a good amount of picts)

Anybody else besides me get all giddy when you see 3g/revised lifters? lol

The Lip of the crossmember seemed like it was gonna be in the way so I cut it. In the picture its only 1/4 of the way cut.

Polyurethane Motor Mount

The lip cut to accomodate the oil pan.

4g63 with Mighty max motor mounts. No modifications done to any of the mounts. Im amazed at how well it fits. Its pretty crazy that it is pretty much dropping in.

The oil pan is resting on the crossmember. So you can see the space the motor needs to drop. But intead of dropping the motor im just going to make a mount spacer and raise the engine. (Hopefully the hood will still shut etc etc)

Drivers side.

Passengers Side.

Since the mounts line up so well i think im just going to live with the shifter location. I will probably end up welding up a custom extended shifter. I just cut room and will close up all the holes later. so all you will see is a shifter in the stock location. I can deal with 4-5 inches away from the stock hole and I still have room for my CAS sensor and water neck.

DoubleJ · Post by **DoubleJ** » Mon Jun 28, 2010 2:29 am

I cant beleive that I had a motor sitting in here a year ago!!! i just got distracted with too many projects / people lol. This time I am hoping to be starting her up in august........

92 GSR-4 · Post by **92 GSR-4** » Mon Jun 28, 2010 4:44 am

Double J,

Great post man, this is an excellent swap.

If theres an issue with raising the engine, you may look into cutting the cross member in the middle, and rewelding it in a fashion that will allow clearance for the motor. That way, the mounts for the rack can still be utilized. If the motor is still hitting the outside parts of the crossmember, you may have to redesign it and get creative with the rack mounts.

Good luck and keep posting!

DoubleJ · Post by **DoubleJ** » Tue Jun 29, 2010 7:59 pm

I put in the spacers and now the oil pan clears everything. put the hood on for a test fit and right before the hood is about to latch all the way down it hits the cam gears. I think i can work around it and notch the hood or something.

Spacers

Pretty good amount of room for the o2 housing and exhaust.

kyle · Post by **kyle** » Tue Jul 27, 2010 12:38 am

Hows it coming man?

I just got evo manifolds and a 16g today. Still trying to source a complete 6 bolt.

I picked up a d50 tranny, but im just afraid it'll blow up in a week, so I'm trying to find a good manual tranny that I can buy a bellhousing adapter for.

Still gotta make sure the turbo will clear the brake booster and steering column. I'll take some pictures of what I've got going so far....

DoubleJ · Post by **DoubleJ** » Tue Jul 27, 2010 1:04 am

Its going great. I havent had much time to work on it. I have a radiator that is in the mail right now. I went with a Godspeed aluminum radiator and it came with fans.

That would be cool to see your progress...

kyle · Post by **kyle** » Tue Jul 27, 2010 1:06 am

Cool man, have you seen the nissan/mitsubishi meet that coming up in Aug? I wish my car was done, thats a perfect first show for it.... haha

Im just not sure about this d50 tranny..... you think its worth fabbing up everything to work with it? Im just not sure its gonna hold up.

DoubleJ · Post by **DoubleJ** » Tue Jul 27, 2010 1:41 am

man........ I need to get this car done! nissan AND Mitsu meet.... that would be perfect!

nicksk · Post by **nicksk** » Fri Jul 30, 2010 3:16 pm

from witch car is the transmision and hosing from
it bolts nice to each other
nick

DoubleJ · Post by **DoubleJ** » Fri Jul 30, 2010 7:25 pm

nicksk wrote:from witch car is the transmision and hosing from
it bolts nice to each other
nick

Toyota Supra - R154 5 spd Transmission

Mitsubishi Mighty Max Motor Mounts

Evo 8 Intake manifold.

what hosing are you asking about?

Arktis · Post by **Arktis** » Fri Jul 30, 2010 9:55 pm

DoubleJ wrote:what hosing are you asking about?

I think he meant housing.

DoubleJ · Post by **DoubleJ** » Mon Aug 02, 2010 12:50 am

OOOooo that makes sense. ( I read it fast )

so yep. R154 5spd with one of bills billhousings

Spoolin4g63 · Post by **Spoolin4g63** » Sat Aug 07, 2010 12:46 am

I'm trying to piece out this same swap, but using a w58 instead of a R154. The problem I foresee myself running into is the shifter location. How do you plan on extending the shifter position? I found this kit online, but at $325, this piece is going to end up costing almost as much as both bills housing and the w58 trans!

http://www.myjzswap.com/ecom/Swap-Kits/ ... d_156.html

How are others extending their tail housings.

DoubleJ · Post by **DoubleJ** » Sun Aug 08, 2010 9:11 pm

Spoolin4g63 wrote:I'm trying to piece out this same swap, but using a w58 instead of a R154. The problem I foresee myself running into is the shifter location. How do you plan on extending the shifter position? I found this kit online, but at $325, this piece is going to end up costing almost as much as both bills housing and the w58 trans!

http://www.myjzswap.com/ecom/Swap-Kits/ ... d_156.html

How are others extending their tail housings.

that looks pretty sweet. Im thinking about just cutting the stock shifter and welding a new piece on....

orrrrr I was going to see if any toyota truck has a shifter that might fit into the r154 that is already bent out and down then back up. some trucks already have a shifter stock thats like the one I want to make.

TsTKl · Post by **TsTKl** » Thu Aug 19, 2010 12:59 am

you probably know this or are ok with working around it, but you do realize that the evo 8/9 turbos are not direct bolt ons to dsm 4g63s, right? The manifold will bolt to the cylinder head, however since the turbo and manifold were designed to be on the other side of the engine after the motor was flipped in the evo 4, they do not account for the extra space needed because of the balance shaft. This buldge in the block makes it so you have to grind down the compressor housing and run a spacer on the exhaust manifold. I think if you run a large enough spacer you don't have to grind down on the turbo, but because there is so much material there on the turbo you can make the spacer required significantly smaller.

I plan on running the evo 9 turbo as well at some point, but for now the evo 3 turbo will have to do. Btw evo x turbos are smaller, on top of being completely different.

DoubleJ · Post by **DoubleJ** » Thu Aug 19, 2010 6:32 pm

(not tryin to be a dick in this reply)

yes i realize they are not a "direct" bolt on. If i wanted to use one I could, i have a spacer etc. butt I actually have an EVO 3 installed. and from first hand experience you can bolt a evo turbo to a dsm.

the story lol: so I sold an evo 8 turbo to this guy and I kept telling him its not a direct bolt on. they kept saying over and over that it will mate up to the evo 3 exhaust. I kept telling him that its not going to work. he bought it anyways.... a week later my buddy calls me up and tells me he sold a dsm part to a guy with a 1G that had a Evo 8 16g. It was the same guy. He put the compressor and center section into the evo 3 exhaust housing. and still got 3-5 pounds!! lol I cant beleive it even ran. Think about it, the exhaust gasses are hitting the blades the wrong way!!! hahah

anything is possible ya know. just look at all of these projects.

Update: no update, i been wayyyy to busy it really sucks because im getting really close to it being done.

Mr Hyde · Post by **Mr Hyde** » Tue Aug 24, 2010 5:34 pm

Double J.

I searched online and couldn't find a creative steel motor mount website.
Who did you order your motor mounts from, whats the part number, and how much did they cost?

Mr Hyde

DoubleJ · Post by **DoubleJ** » Tue Aug 24, 2010 5:57 pm

Mr Hyde wrote:Double J.

I searched online and couldn't find a creative steel motor mount website.
Who did you order your motor mounts from, whats the part number, and how much did they cost?

Mr Hyde

http://cgi.ebay.com/ebaymotors/89-90-91 ... ccessories

$100

Mr Hyde · Post by **Mr Hyde** » Tue Aug 24, 2010 9:24 pm

Thanks for the link!

DoubleJ · Post by **DoubleJ** » Sat Sep 25, 2010 4:53 pm

Quick Update:
I am using a GVR4 water neck that doesnt have a cap. I had to reweld the neck so that it wouldnt run into the firewall. The cap is on the radiator.

DoubleJ · Post by **DoubleJ** » Sat Sep 25, 2010 5:26 pm

How the car sits now:

Godspeed Alluminum Radiator

using the stock 240sx throttle cable

JDOliver · Post by **JDOliver** » Tue Sep 28, 2010 1:44 pm

Looking great DoubleJ.

Want3d · Post by **Want3d** » Fri Oct 29, 2010 8:19 pm

Man your really impressive!! this gives me alot of motivation to build something similar to your project!!

DoubleJ · Post by **DoubleJ** » Wed Dec 01, 2010 2:19 am

If only I had more time! The things i could accomplish lol. Wish this thing would be done already. Been way too busy. But no rush and its fun when I have the time.

New suspension pieces:

DoubleJ · Post by **DoubleJ** » Fri Apr 01, 2011 12:11 am

Finally took 3-4 hours to work on the car. Found out that the motor mounts pretty much lined up.

SOoooo.. recapping the project. Using mighty max motor mounts. small spacer, R154 Transmission. And a small spacer for the trans mount. Everything bolted in lol. It was pretty easy.

Im really suprised more people arent doing these swaps, especially with how many parts there are for the S chassis and how well this is all fitting together.

Update Pictures:

Cut and drilled these pretty quickly.

Spacer Upside-Down

Notice the top of the picture I cut the shifter hole larger.

The Toyota trans mount holes lined up with the chassis holes. But the trans was pointing towards the rear passenger side too much. so to straighten it I drilled my own holes on the edge.

On the other side I just made a spacer because on the Nissan this side of the stock mount is higher. (The R154 trans mount is flat instead of offset like the nissans)

I forgot to take of the center mount. Wont be needed.

DoubleJ · Post by **DoubleJ** » Fri Apr 01, 2011 12:44 am

Modified water pump. The water neck came off of some chevy car. Even has a nice fitting for a turbo water line.

Not the prettiest but it works.

DoubleJ · Post by **DoubleJ** » Wed May 04, 2011 1:17 pm

I went to the local driveshaft shop and had them make me a one piece driveshaft. I supplied a toyota yoke and the nissan driveshaft. They ended up just using the toyota yoke and supplied all new parts (bearings etc). That cost me $315. And i payed $35 for the toyota driveshaft. So the total cost was $350 for a custom toyota to nissan driveshaft.

When you look at somethin like this it definitely makes you feel good about the drivetrain.

Next is fitting the fuel cell...

omgosh · Post by **omgosh** » Sun May 08, 2011 4:06 am

Just registered for this thread

So you're using Mighty Max mount brackets, and 240sx poly mounts right? Also, how much did you spend getting the evo intake manifold to match up?

DoubleJ · Post by **DoubleJ** » Mon May 23, 2011 1:09 am

omgosh wrote:Just registered for this thread

So you're using Mighty Max mount brackets, and 240sx poly mounts right? Also, how much did you spend getting the evo intake manifold to match up?

Yep. It was around or under $100. I took it to 2 different places. Probably would be cheaper to have one shop do all the work.

DoubleJ · Post by **DoubleJ** » Mon May 23, 2011 1:09 am

Update:

The new welded water pump peice is in the way of the power steering bracket and pump. Looks like I will run no power steering until I find a electric pwr steering pump or a different solution. (MR-2 pump etc) Of course I could swap out the water pump, but I like the setup and I just wanna get this car running.

If the guy who welded the peice did a better job and made it straight I probably wouldnt have this problem. Sort of my fault because I didnt factor in the bracket etc.

All of that aside the project must go on.

(Starting to look like a 'real' engine bay!)

Painted Water Pump -

Jay racing Alternator relocation kit. I highly recommend this kit if you want to change your alternator location. Its pretty pimpin. -

I also deleted the ISC and made a blockoff plate and gasket. (not pictured)

DoubleJ · Post by **DoubleJ** » Mon May 23, 2011 1:12 am

Update: (Me acting like I know what im doing lol....)

With the alternator relocation the belt was pretty close to the
motor mount so I grinded it to make room.

Next, Intercooler piping:

How its sitting now.. more to come......

Kind of dreading the wiring harness but its coming up soon....

omgosh · Post by **omgosh** » Tue May 24, 2011 11:14 pm

What are you planning on using for an ECU? I would suggest one from a 2001-2005 MT 2.4 3g Eclipse, federal model. They are the same hardware as the Evos and can be reflashed with free software. LMK if you have any questions..

Also have you seen the guy on Ebay who does custom shifter extensions for like $225? That might make life a little easier.

DoubleJ · Post by **DoubleJ** » Wed May 25, 2011 12:56 am

omgosh wrote:What are you planning on using for an ECU? I would suggest one from a 2001-2005 MT 2.4 3g Eclipse, federal model. They are the same hardware as the Evos and can be reflashed with free software. LMK if you have any questions..

Also have you seen the guy on Ebay who does custom shifter extensions for like $225? That might make life a little easier.

I am using a chipped ECU. Eventually would like to go to ECMlink.

$225 is a bit pricey for this swap. trying to keep cost down. I have definitely thought about buying an extension though.

DoubleJ · Post by **DoubleJ** » Wed May 25, 2011 12:59 am

omgosh wrote: Also have you seen the guy on Ebay who does custom shifter extensions for like $225? That might make life a little easier.

Just wanted to make a point of how straight forward this swap has been. Really, this is the only major "problem" that Ive had. I might have a small issue with the hood closing but im not too worried because there are simple ways to fix that. (its really close, barely hits the timing cover before latching.

You read all these forums of how hard it would be to swap but I hope to see more of these. Especially with how balanced these chassis are and the availabilty of parts.

jjrock5 · Post by **jjrock5** » Wed May 25, 2011 9:21 pm

How do you plan on implementing (connecting) the Evo TPS (since you're using an Evo intake mani) with a DSM harness?

Arktis · Post by **Arktis** » Thu May 26, 2011 12:41 am

DoubleJ wrote:I am using a chipped ECU. Eventually would like to go to ECMlink

As an ECMLink user, you will never look back once you get it.

You can use an ECMLink until the day you die, and you'll never run out of features. You'll pretty much be making this face the whole time.

TsTKl · Post by **TsTKl** » Thu May 26, 2011 2:13 am

jjrock5 wrote:How do you plan on implementing (connecting) the Evo TPS (since you're using an Evo intake mani) with a DSM harness?

wouldn't it work just like a 2g? Just move the idle signal wire over to the harness and call it a day?

DoubleJ · Post by **DoubleJ** » Thu May 26, 2011 2:19 am

TsTKl wrote:
jjrock5 wrote:How do you plan on implementing (connecting) the Evo TPS (since you're using an Evo intake mani) with a DSM harness?
wouldn't it work just like a 2g? Just move the idle signal wire over to the harness and call it a day?

Im sure its something simple like that. I just havent done the research yet.

Edit: if you can use a Evo 8 ECU in a 1G and 2G. And if you can use the Q45 TPS. It should be pretty straight forward and work.

DoubleJ · Post by **DoubleJ** » Sun Sep 18, 2011 12:45 am

Update! lol I bought a 37 degree flare tool (makes hardlines fit up to -AN tube sleeves) and flared my stock gas hardlines. Also I cut out the trunk for the fuel cell. Im in "just get it done mode right now." Also I mounted the fuel pump and mounted the methanol pump and reservoir.

I will probably use some sheet metal to enclose this later

$30 37 degree flare tool

Pretty dirty. Waiting till i can move the car and pressure wash everything

Battery location behind the passengers seat

92 GSR-4 · Post by **92 GSR-4** » Thu Sep 22, 2011 8:00 am

Wow....Great build. Keep it up!

stockfornow · Post by **stockfornow** » Thu Dec 01, 2011 9:35 pm

This is awesome! I have 1G DSM (collecting dust in storage

)... Anyway, I've been involved a little bit in drifting and such, and I was thinking about doing this swap, I'm glad you're doing it. I can't believe that it's almost a bolt in

I might just have to buy another 240sx just so I can put a 4G63 in it! This time in my 240 I went with a 1.5JZ swap since my buddy had a few jz engines laying around, and I wanted a lot of torque.

And may I post a couple of these pictures on the nissan forums?

90awdtsi · Post by **90awdtsi** » Mon Feb 13, 2012 1:50 pm

any updates on this project?

Project Zero G Forums

Project: 89 240sx Coupe w/ 4G63

For DoubleJ

Re: For DoubleJ

Mounts