bigjohns 4g63 swap

[Big John]

ok fellow questers i thought it was time for me to share the story of my qutst and my build. it all started about 2 years ago when i had driven my quest to work.

 

here it is before things went downhill.

http://i1286.photobucket.com/albums/a610/bigjohns87/motorthen_zps8f76da3c.jpg

 

on my way home oil started spraying on my windshield and it just died. so when i got it back home my son (conquest tsiguy) and i pulled the head off and this is what we found.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/oops_zps3853873c.jpg

 

here is a better pic.

 

 

http://i1286.photobucket.com/albums/a610/bigjohns87/IMG_20120822_153504_zps9dcb7c55.jpg

 

we still don't know why #2 melted but it did. So what do i do now? rebuild mine or do a swap, well 4g63 is what i decided to go with and i would have not even thought about doing it if it had not been for a super nice quester (dsmconquest). just can't say enough good thing about him he was so helpful. ok so i ordered my engine from tiger japanese auto and here it is as i got it.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/engine1mo_zps26d4d320.jpg

 

http://i1286.photobucket.com/albums/a610/bigjohns87/engine2i_zps245210bb.jpg

http://i1286.photobucket.com/albums/a610/bigjohns87/engine4_zpscd67285a.jpg

 

got it up on the stand and cleaned it up replaced the timming belt front cover and rear seal

http://i1286.photobucket.com/albums/a610/bigjohns87/4gonstand_zpsa169573c.jpg

 

while i was working on the engine i sent the quest to my painter for fresh paint allover even under the hood

http://i1286.photobucket.com/albums/a610/bigjohns87/underhood_zpsee3f417e.jpg

 

ordered my cx racing ic and pipe kit and built a bracket to mount it.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/bracketic_zpsb7f2ac89.jpg

 

here it is mounted.

http://i1286.photobucket.com/albums/a610/bigjohns87/icbracket_zps3c9feeb0.jpg

 

dsmconquest suggested to cut the firewall for some added room so i did and built a box to fit in the hole i cut

http://i1286.photobucket.com/albums/a610/bigjohns87/fwallbox_zps08035091.jpg

 

back to the engine, there was a few ways i could go for the exhaust manifold. use the stock one, get the forced performance cast 2g manifold, or go with the tube top mount. i went tith the fp 2g cast manifold which i sent to firefox coatings to get ceramic coated.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/fpmanifold_zps9ac53da7.jpg

 

i now had to decide what turbo to use so i took 2 pain pills and started looking and asking and decided on the holset hx35 and a bullseye performance hot side housing.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/turbomount2_zpsa7832177.jpg%5B/img

http://i1286.photobucket.com/albums/a610/bigjohns87/oilfeedline_zps5d7c5f8f.jpg

 

for the water neck i made a thick plate and clocked the t-stat housing to give more room in the back and used some an fittings to route the upper radiator hose.

http://i1286.photobucket.com/albums/a610/bigjohns87/tstat_zps37f36180.jpg

 

i call my good friend bill hincher to help on the motor mounts,bell housing, transmission mount,shifter relocator,and drive shaft he is the man he is the best thank you bill.

http://i1286.photobucket.com/albums/a610/bigjohns87/waterpumpoutlet_zpsf2071f59.jpg

 

the transmission i went with is the 5 speed supra tranny with the steel center section.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/tranny_zps3660ab70.jpg

 

i used the dsm o2 housing with a tial 38mm waste gate but i had to get it in a kit form and have it welded up to turn down in the back.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/IMG_20120302_172348_zpsfbcc3c85.jpg

 

i changed out the oil filter housing with a new one from a mighty max (it has no oil cooler lines) and that is where i get my turbo oil feed line.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/oilfeedline_zps5d7c5f8f.jpg%5B/iM

http://i1286.photobucket.com/albums/a610/bigjohns87/tank_zpsd28da620.jpg

 

more to come stay tuned

[89BananaQuest]

Nice work so far man!

[NikoFab]

woohoo! very nice!

[nightwalkerancestery]

Awesome swap! My second engine choice behind a 2jz. My friend has a 4g63 AWD Eclipse. It's a nice car but I strongly prefer RWD for balance and practicality. Keep it up! I could use your thread for the swap if I ever chose a 4g63/64! Lookin good!

 

- Charles

[EVOMINUS]

nice going friend...

Did you match port the 2g manifold with the 1g head?

[traps]

Looking good sir!

[kidjc]

Alright Big John! Look'n forward to see'n this bad boy !!!! Looks really nice!

[19cturbo]

get the rest of those pictures up here john, and ill post up the video. dont want to spoil anything.. lol

[Tman]

looking great my friend

[19cturbo]

here is a picture of the start of the wiring, i put alot of long hours into this lol, not near as many as john, but ive been keeping up.

 

http://i223.photobucket.com/albums/dd23/19cturbo/A237331D-2C90-417F-87DB-F90A24AFEE00-25924-00001350ED86B798.jpg

[GLHS]

Looking good can't wait to see the out come

[nightwalkerancestery]

If I had to do that wiring I think I'd need some of those pills in that basket Lookin' good!

 

- Charles

[19cturbo]

the wiring was for sure a headache, we spent around a week and a half on the wiring, and getting everything out we thought we needed out. once we got the harness to what we thought was right, we had some trouble shooting, and had to go back and re work a few things. its good to go now...

[Big John]

well when i got everything ready i got it all bolted together and ready to put in.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/engtrannyhang_zpsa5fe8102.jpg

 

and here it is in my car.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/infront_zps4d6f7cf7.jpg

http://i1286.photobucket.com/albums/a610/bigjohns87/intakeside_zpsc7859fb8.jpg

http://i1286.photobucket.com/albums/a610/bigjohns87/turboside_zps34bfeea2.jpg

 

then came the wiring,i wouldn't even start this without the help of mike (19cturbo) and kirt what good friends to have. you have already seen a pic.that mike posted and here is another.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/wiremess_zps8f11c590.jpg

 

for those who are interested i used a 1g dsm wiring harness and a 1g eprom ecu that i had a socket installed. i am using a ostrich 2 emulator whish is mounted to the ecu and jackal software.

 

http://i1286.photobucket.com/albums/a610/bigjohns87/1330106367892_zpsc74be591.jpg

 

video to come stay tuned

[19cturbo]

Here is a video of the car idling like a champ, we have had some speed bumps in the tuning process to. but i think we are getting through them and this thing is just about to be alive.

 

Edited October 5, 2012 by 19cturbo

[Big John]

it seams to be running fine now but i still have some things to finish up and it will still be a while before its on the road. will keep everyone posted. john

[HotrodTSi]

Glad to see this coming together John!

[importwarrior]

have any transmission mount pics?

[IntercooledFlatty]

nice work

[302ci]

Wow looks awsome cant wait to get mine going but im in a delima on the turbo lol. I can tell from your pics a 20g with a fmic jpipe wont work. But would i be able to turn the compressor housing to get it to work or should i just get a 14g for now and use it til i get the fuel set up for a Holset.

[19cturbo]

If your not keeping the A/C it would be a whole lot easier. Move the alternator where the ac compressor is and the turbo will be wide open at that point.

[Big John]

inportwarrior if you go to the engine swap forum then go to the motor mounts and shifter relocators you will see the trans mounts john

[Starfyter]

^{Beautiful. How did the firewall clearance end up? Would you have been able to use the AN water line without cutting the hole?}

^{That turbo is awfully close to the frame rail. Lol. Nice clean looking intake mani. Did you weld the rear or just bolt a sealer plate on?}

[19cturbo]

The hole in the back is for the water outlet, and for the cam angle sensor as well, i would venture to say you could cut a smaller hole and still make it work but it would be close. remember, this engine was made to set in sideways..

 

the turbo is very close to the frame rail, a top mount manifold would have taken care of that but those bad boys are pricey (1200+) so he had to make do with what he has. The strut tower took a little massaging with a BFH but he has made it work. If he were to get rid of the A/C and then he could move the alternator to the other side, the turbo would be open in the front.

[Starfyter]

Yea, the 6-Bolts have the CAS in the rear, that's why I'm planning on doing my swap with a 7-Bolt. I might be picking up a guys '96 GST for cheap, so we'll see what happens there. Right now my biggest concern is water route and intake manifold. I'm looking at doing a fully stock swap so it'll pass CA engine swap regulations.