Project Zero G Forums

I've been lurking on this site for some time gathering all my research for my swap, figure now is probably the best time as any to post up now that I'll be entering the actual swap phase very soon. Anyway, the motor is out my 91 Galant VR4, but due to some serious cancer on various parts of the underbody, i finally gave in to scrap that idea and move onto something with less rust!




I had the whole motor built up, so it should be a pretty sweet ride once it's done, hoping to have it back on the road by sometime this winter.

Motor as it came out of the VR4







New Eagle 100mm Crank


Tuning will be done with Megasquirt (keeping an eye on that MS thread) I'm pretty sure it's a MS2 board, has the MapDaddy 4 bar added on already (friend built it a few years ago). I still need to put together the harness for the board itself.

I suppose to keep it short and sweet, here's my build layout of the motor. Suspension will be the next project down the road as I do want to set the car up for doing some weekend drifting. Also have all the parts to convert the fugly exterior to a Australian GC Galant

HP Goal
350-400hp

Bottom End
Wiseco 85.5mm 8:8:1
Manley H Beam Rods
Eagle 100mm Crankshalft
Boss Innovations Main Girdle

Bearings and hardware
ACL Race Rod Bearings, STD size
ACL Race Main Bearings, STD size
ARP Head Studs
ARP Main Studs

Head
Manley Single Springs and Titanium Retainer set
Delta Cams 272 Camshafts

Transmission
Supra R154 Trans with a Billhousing

Fuel
Galant VR4 Fuel Tank
Walbro 255lph fuel pump
Aeromotive AFPR
RC 750cc Injectors

Misc other parts I have
Subaru Alternator
Modified Aluminum Mustang Alternator Pulley
Intercooler - Will have to contact ETS
External Oil Cooler
'90 DSM Oil filter setup
Mighty Max motor mounts
1G DSM Harness (My VR4 harness was in bad shape)

Left to do/buy
BSE
New Oil Pump
SOHC Waterpump
Timing kit
IAT sensor
Fuel Lines
Evo 8/9 turbo setup
JMF Intake Manifold
Front Water Outlet conversion
Hilux Rearend
Driveline
Intercooler
Adjustable Cam Gears

looking forward to your progress

I noticed that a Subaru alternator was on your list. I've never seen a mod with that. What's the deal? Also, know that you will need a custom manifold or spacer to run the newer EVO turbos as they hit the block on the stock manifold.

Didn't know that about the stock evo manifold, good to know. The scoobie alternator is suppose to be a 110amp alternator, a buddy machined down a aluminum mustang pulley to make it work on the 4g63. It's actually still a Mitsu Alternator, just happens to be off a Subaru.

Picked up the trans, bellhousing and all related little pieces. Just need to research which starter I'm suppose to use and throwout bearing. Already have a suitable clutch disc just need to buy a pressure plate.

All 4G63 starters should be the same. As for the TO bearing, you might consider just getting the whole setup from Bill. You either need to find a whole replacement TO bearing new, or press the old bearing off the Toyota unit and press on a new one. The new unit will be less painful.

I was thinking more on the ends of which starter, Mitsu or Yota, but I found my answer. Before I was just going to go with the W58 instead, but couldn't pass up a good deal on the R154 with one the "Billhousing". By whole setup what do you mean? Maybe I should search more.

Bill now has a TO bearing setup so you don't need to source parts or hope things work together.
To piece this setup together you would need:
Mitsu Clutch fork
Mitsu pivot ball
Toyota TO bearing sleeve (or whatever it's called)
Toyota TO bearing

He can also set you up with the right pilot bearing (Mitsus don't have one) and the right disk. Should just be any 10" Toyota disk, but check first.

I have the Clutch fork, Pivot ball, Clutch disc and these were in a small plastic bag


So basically, out of the parts you listed I just need the pilot bearing, TO bearing and sleeve.

any progress?

More soon! Just got laser eye surgery on thursday, so any wrench turning at both work and on this project are on hold till my eyes heal up.

take care of that!! my wife had that ten years ago she was like a kid seeing things for the first time

Scheduled time off from work early next month so I can get things moving again. Engine brackets arrived today, making another run to Vancouver this weekend to pick up the hilux rear end a buddy has been holding for me. That's about it for now.

Engine side brackets


Gotta order a Master cylinder, Slave cylinder, VSS from Marlin Crawler to convert the speedo cable setup to electronic on the R154.[/img]

can't wait

Here's my Intercooler and Starion Clutch Pedal


Had other stuff come up a few weekends ago so I never made it down to get the rear...however heading down in the morning to get it. New Aluminum Radiator on the way. I'll take pics starting Wednesday as I tear the car apart and start mocking up everything. I keep going back and forth about using the front outlet vs the rear and I'll probably just run it from the rear of the head, personal preference to not take the chance of any leaks on or around my timing belt. My luck something will leak there lol.

Narrowbody Hilux Rear end - Rear Disc Conversion in the future, sometime way after the car is on the road again, drums can stay till then!


Front case I will be rebuilding instead of dealing with the one originally off the motor, more than likely that one would be like the rest of the vr4, snapping bolts left and right..





Gears aren't too bad, however I'm getting new ones regardless!

Shortblock

Progress. Should have the rear in before the end of tomorrow and the engine pulled. Had a minor setback with leaf alignment..

Welding the new leaf mount brackets tomorrow then it will be time to pull the motor and getting things ready to drop that thing in!

Held off on welding the leaf shackles till the trans gets sorted out so we can get a good idea of what angle we need the pinion for the rear differential at.

Getting closer though!






Probably my favorite pic so far!

looks like your keeping busy. is that grille uniquie to that year. i'd like to find one like that

In a way it is, it's not a USDM grill, it's off a '75 Aussie GC Galant Coupe.

Turn indicators are being relocated elsewhere once I convert the 7" single lamps to the quad 5 3/4 headlamp setup.

what are those engine brackets and were you able to purchase them through the dealer?

Mighty Max 2.4 brackets MD041030 and yes I ordered through the dealership. MitsubishiParts.net is tied to the local dealership out here in WA. Took about two weeks for them to come in but I didn't mind waiting and they were around $30.

RaptorReed wrote:Mighty Max 2.4 brackets MD041030 and yes I ordered through the dealership. MitsubishiParts.net is tied to the local dealership out here in WA. Took about two weeks for them to come in but I didn't mind waiting and they were around $30.

thanks

updates, who doesn't like updates!
Engine Harnesses, Left is a modified 1st gen DSM harness already setup for a RWD app and Right is a stock Galant VR-4.



Modified Harness, sub harness with fuse box is for all the ECU constant 12v, and any other accessories (fans, etc). isc, o2, closed throttle switch, and bcs were all removed, I still need to remove the MAF plug from the harness though as I won't be needing that. Still has the plug for the diagnostic port, which I may still use because I have a datalogger cable from my old VR4.



The VR4 harness I'll just keep for spare parts and what not.


New bellhousing for my R154 that arrived a few days ago from Bill! Thanks again!




Thermostat Housing with 4g37 water neck, maintaining the coolant flow to the rear of the head. Sure I could have changed it to the front, but I personally rather keep any many fluids away as possible from the timing belt and I didn't want to do any more work on my new head.

Turbo arrives this weekend hopefully! It's starting to pick up pace again.

What turbo?

FP Red

Double post ftl...

Nice, we've done evos that make over 500 hp@ the wheels with e85 on a green so a red is over kill for the power you want. But if a little's good a lot must be better
Also maybe i missed it but why run ms? an evo 8 ecu would do the trick quite well.

I was going to run MS because I always wanted to, but I'm leaning back towards link, I'd be hard pressed to find someone local that can help with tuning on MS. Evo ECU is an idea, but that would add to parts, because I would need a Evo Ecu + jumper harness to make it a plug n play ordeal.

The Red is overkill, but I got it for a good deal from a buddy, so I went for it. E85 is not widely available around here so I'll be staying on 92.

Link I think would be the best option, plug n play and easy to tune. I'm running link on my rally raid project as well.

Good progress, but those wheels are terrible. I sure do miss this thing.

Yes they are lol, they are just the wheels that came with the axle, more than likely I'm going to be running Widebody starion 16s or some 15s.. Fronts, need starion hubs and struts to finish the 5 lug conversion. Who knows, maybe you will see her again at next year's shootout if I can make the drive.


At least she's in good hands now, all the chassis wiring (front end, interior, trunk, etc) is being replaced (no more bus fuses , new gauges soon, dash pad I'm pretty much SOL for, but yeah not just the motor getting swapped .

R154 is mounted finally!

high def pictures later.

Cutting the the trans hump out, that was my only problem since the KM110 is much smaller than the R154 and even a KM132 at that lol.




the stock cross member has to be repositioned to suit the new trans, it's a few inches off from fitting. Nothing a little bit of making/welding our own studs on won't solve with the current holes in the frame supports on either side.

need to make some adjustments to fix this, we don't want to have to cut through the cross beam sections. It can actually sit lower than this if we remove the stock cross member which is supporting the trans to allow the car to remain mobile in the shop. Plan is to angle the motor just a tiny bit to the sweet spot where the tailshaft housing clears the tunnel just enough.

Ever so slowly starting to get back to work on this...just picked up a set of 5lug starion hubs, calipers, knuckles and widebody struts (until I can get ahold of flatty ones) to finish the 5 lug swap.

Snagged a pickup km132 trans crossmember which looks to be the perfect size with a little modifying to suit both the R154 and bolt to the car. Starion crossmembers are too damn short lol compared to these early cars, which like the trucks, mount to the frame rails.

Get'r done kid >;o)

5 lug swap pretty much done . Next step is remove remaining brake and fuel lines in the engine bay, wash out, clean, and start prepping the bay for the motor. Pickup gas pedal bolted up perfectly, just need to bend the rod a little to have full swing. Already took measurements for the new brake lines and estimation for the fuel lines. Need to mount the wilwood pedal assembly still as well.







I think after the brakes and fuel stuff are sorted I will be ready for the motor. I don't think I'm going to run a heater though, a bit complicated if I run the tstat up front.

LOVE the updates!

I Need to get down there and cut out that piece of metal I need from you.

Be a few weeks to month, but I'll be starting this project back up soon enough!

Need to get some widebody Starion Control arms too . Another suspension conversion.