4G63/4G64 2.4L Build - The List

[Fitz7099]

Hey guys and gals. I'm John and I'm into originality. With that being said, I want something original. So what does that lead me to? A 2.4L! Ok ok, it may not be that original, but it will be fun

That's the list I just drew up in the last couple of minutes, I'm sure I made a mistake somewhere.

My Goals (since so many engine build threads never have any)
It will be my daily driver; literally DAILY driver as it is the only car I own. It must be mostly reliable. It will see the strip only a hand full of times a year, it will see road courses a few times a year, and I may do autocross with it. My power goal is 400 horsepower at the wheels on 93 octane (pump).

With that being said, here is the list.

Engine Block:
4G64 Block (out of an automatic)
4G64 Crankshaft
Eagle H-Beam Rods
Weisco/Ross/etc Pistons
Balance Shaft Removal Kit
ARP Studs
1G "Big" Rods

Engine Head:
1G Head (will later be ported and polished)
1G Intake Manifold
Tubular Exhaust Manifold
4G63 Cams (will upgrade after the break in)
4G64 Cam Gears (will upgrade after the break in)
1G Cam Angle Sensor

Turbo:
Ported Big 16G (for now, instaboost? will upgrade later)

Fuel:
Walbro 255LPH High Pressure Pump
750cc or Larger Injectors
Fuel Pressure Regulator
NGK BPR7ES Plugs
GM Translator
3" GM Mass Airflow Sensor
DSM Link

Misc:
OEM 4G64 Timing Belt
Resurfaced Flywheel
Front Mount Intercooler



What do you guys think?

Edited: 1/23/07 12:24pm - goals
Edited: 3/23/07 8:15 am - Title from "4G63/4G64 2.4L Build - The List" to "4G63/4G64 2.4L Build - The List [Update w/ Questions]"

 

[canucatchdis]

The list looks ok. Check out this forum I posted up a bit ago.

http://www.dsmtuners.com/forums/showthread.php?t=247530

I can also send/ email you the actual excel document that I have, if you would like.

 

[scotthidley]

Figure out what cams you want now as some require better springs. Don't forget a good head gasket. You may want to hold off on the manifold until you figure out which turbo you want as well (internal vs. external wg, as well as turbo housing options,...). I don't see a clutch in there either, but it's a good time for a new one.

 

[Fitz7099]

The list looks ok. Check out this forum I posted up a bit ago.

http://www.dsmtuners.com/forums/showthread.php?t=247530

I can also send/ email you the actual excel document that I have been working on, you would like.

That would be good. I'll PM you my email address.

Edit:

Figure out what cams you want now as some require better springs. Don't forget a good head gasket. You may want to hold off on the manifold until you figure out which turbo you want as well (internal vs. external wg, as well as turbo housing options,...). I don't see a clutch in there either, but it's a good time for a new one.

I know next to nothing about the drive train. What is a good streetable clutch? ACT 2600?


Feel free to give me suggestions and input


Edit x2: Update my goals in the first thread. My minimum goal for wheel horsepower is 400 on 93 octane (pump).

 

[scotthidley]

I'm not happy with the 2600. I'm looking at going twin disc as it'll be much lighter, and lower pedal efforts, but I have much higher power goals too. The 2600 definitely gets the job done, but after going through multiple pedal assemblies and clutch hydraulics, I've had enough of it. TEC over at dsmtalk said he runs a ACT 2100 plate with a feramic disc making 550hp, daily driven. I don't know what companies disc, or what step height he's running, but that sounded like an interesting setup. Whatever you get, you want a full face disc,the spacing between the 2 friction materials has a marcel spring. This sprig is what allows you to have a smooth go from a stop, unlike the puck style discs that are on/off switches. A 2100 with street disc will slip a bit too much if you launch the car (the 2600 can, but you have to feather it yourself to do it pretty much). I'd recommend an MLS head gasket as well. Mitsu, Felpro, Cometic, and HKS all make them. The Cometic worked for me, but I was making ~ 300 whp tops, so I really wasn't pushing it. I'm going to a Mitsu one this time around.

 

[jpbrazill]

When you start building the 2.4, you are going to have some clearance issues here and there. For instance, the timing belt cover bolt holes will not align accordingly with the head. Also, you will need to fabricate or extend your turbo oil drain line a half inch in height.

Other than that, you need to add a 2.4 timing belt to the list. If you have trouble finding one, go to Checker (no where else) and look up a Hi-Tech timing belt for a 1994 Galant with a 2.4 DOHC.

 

[Fitz7099]

Little update:
Picked up some MDS 8.5mm wires and NGK plugs.
Just picked up a freshly rebuilt 1g head for $130 and a pair of 1g cams for $10!
Off to the shop they go to be checked against oem specs.
Still looking for a good block before I go off and buy the rods and pistons.

Question: What size injectors do you think I should be running? I will be tunning this myself (without a dyno) with DSMLink. Also, to any one who has done this build before, what pistons/rods did you use and how were your experiences with them?

Edit:

1g Head:

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[Dorifto]

Looking good. I like the parts outline, very informative.

I want to attempt a 4G64 swap into my '92 GS-X, and the info you've provided thus far is invaluable. Thanks, and good luck on the build!

 

[kambonate]

everything looks good. im in the process of doing one myself. 4g64/4g63 in a 2g.
our setup sounds somewhat alike.
Engine Block:
4G64 Block (out of an automatic)
4G64 Crankshaft
Eagle H-Beam Rods
Weisco/Pistons
Balance Shaft Removal Kit
ARP Studs

Engine Head:
2G Head (will later be ported and polished)
2G Intake Manifold
RnR Ram style Exhaust Manifold
HKS 272 Cams
4G64 Cam Gears
2G Crank Angle Sensor

Turbo:
Garret BB-50Trim

Fuel:
Walbro 190LPH
780cc Larger Injectors
NGK BPR7ES Plugs
DSM Link

Misc:
OEM 4G64 Timing Belt
SBR 4000 Clutch
8lbs Flywheel
Front Mount Intercooler
Your Basic BPU+

 

[Fitz7099]

Just a little update to the purchased parts list:

Recently purchased items:
95 EPROM ECU
MDS 8.5mm Wires
NGK7ES Spark Plugs

Still looking for that block and crank

I now need to decide on what injector size I need before I order DSMLink. I haven't looked into it too much, but the general word for big HP goals is to get 1000cc injectors and nothing smaller.

Will 1000cc injectors be enough for 500hp with extra room to grow or will the 1000cc be at max duty cycle?
What are the differences between the different types of injectors? Is one type superior?
I'm guessing I would new a Walbro 255 or 255HP to support these - would it be a good idea to upgrade from the 190 to the 255 or 255HP?

 

[Fitz7099]

Look's like Ill be going with 950's or 1000's

 

[kambonate]

well my Rods, pistons and bearings are all here and i just dropped then off at the machine shop and hopfully i should be getting it back sometime nextweek ### i have to drop off the ARP head and main studs when they get in on wendesday. So im think myabe friday of nextweek i should have everything done.
1000cc will be more then enought for only 500hp. Im running 780cc on my setup but im only shooting for 400hp Daily so. thats more then enought my my setup. also run a 255hpl. im doing that as well.