Evo III Motor swap info in here

[stickman]

I recently put a rod and my balance shaft through the side of my block and decided to get an Evo III longblock insted of replacing it with a 6-bolt. I figured I would take the time and list a few of the things I had to swap over from the old block to the eVO MOTOR.

Cams

The cams are almost identical except for one thing. The 2nd gen Cam sensor screws into the passenger side of the intake cam. The Evo motor has the cam sensor on the actual cam gear. Solution?? I pulled the cam out of the 2nd gen head and swapped it into the Evo head I did pull out the micrometer to measure the lift on the cams and the 2nd gen has a higher lift than the evo. Not much but there is a difference. I didn't measure the exhaust cams though :-/

The valve cover has a few differences. It actually says Mitsubishi on it ;-D But for now my valve cover went back on, it was cleaner.


Intake manifold

The intake manifold on the evo has shorter runners and a bigger throttle body. The throttle cable connects on the opposite side of the throttle body. I just pulled the manifold, fuel rail and manifold bracket and replaced it with my 2nd gen stuff. It all bolts in just fine.I'm sure you could use the intake from the evo but I just wanted to get the motor back together. On a side not I have an evo manifold and throttle body for sale, PM me with an offer hahaha.

Exhaust Manifold

Since I am using a DNP tubular manifold and a small 16g, this was kinda a no brainer for me. My evo motor came with a smaller turbo than the 16g so I just pulled it off and replaced it with my exhaust parts. I did measure the prots and the exhaust ports on the head and manifold are the same height as my 2nd gen but they are about a 1/4 inch wider on the evo. Another side note, i have a small turbo from an Evo with the internal wastegate and an Evo manifold sitting in the garage, PM me if interested ;-)

Timing Belt

All of the timing components are exactly the same as the 2nd Gen. And yes it is still a pain in the arse to set the timing I hate being one tooth off . Balance shaft belt swaps over as well. The water pump was kinda crusty so I swapped my good one on there. Bolts up just fine.

Cooling System

Hmm, where to start. First off, the thermostat is exaclty the same. However; the thermostat housing is a bit different and the water neck that runs under your exhaust manifold is different as well. Again the parts swap over and bolt up fine. I swapped over all of my turbo lines as well. The oil cooler on the turbo is a little bit different. The lines were in different places, so I swapped that as well.

Power Steering

The power steering pump and bracket are different than the 2nd gen. I swapped mine over just because I don't want to have to buy a JDM power steering pump if the one on my car ever dies. If you do not change the bracket when you put the 2nd gen pump on, you will not be able to put one out of the 4 bolts back in when you tighten the belt.

A/C

Again the bracket for the a/c is different on the evo motor so I swapped my a/c pump and bracket over as well.

Motor Mounts

Finally I catch a break. The new block only has 1 motor mount on it and guess what??? It's exactly the same as mine, woohoo!!!!!

Alternator

Again, I pulled my bracket and swapped it over, just to be safe ;-) I did have to take my 3 month old alternator back to the parts store. For some reason a whole quart of power steering fluid cause a short in the alternator, who would have thought that??? Warranties rule!!!

Transmission/Flywheel/Clutch

All three bolt up fine and the crank is a 7-bolt in case you were not sure.

Oil pan

I think the oil pan is a bit deeper in the deepend and shallower in the shallow end. it's kinda hard to tell because my old one has about 4 hols in it. I do seem to have a bit more clearance while installing my transfer case though.


So all in all the swap went fairly well. I did have to replace a few more gaskets and O-rings than I had originally planned but better safe than sorry. The turbo seems to spool faster and the car seems more responsive. I don't know whether or not to attribute that too the motor being fresher, the exhaust ports or if the exhaust cam has a long duration or lift( did not measure that :-( ).

I hope this post helps anyone that is interested in getting a "JDM" engine. I only did it because it seemed like the best option for me at the time. Feel free to ask any questions if you have them. I will update later with pics. I seem to have misplaced my digi cam somewhere hahaha probably in a box full of car parts.

 

[TurboAnything]

I dont think that you have a EVOIII motor. If it came with a TD04hl the it was out of a minivan of some sort in japan. The EVOI-III and that van motor look the same but have different turbos and cams pistons. That is why the cam had less lift then the stock 2g.

 

[Spyder4g64]

1. Evo III motors came with a TD05H turbo, known as the evo III 16g, .
2. Cyclone Intake Manifolds
3. EvoIII = 6-bolt
4. 510cc Yellow Top Injectors
5. You bought a "mini-van" variant of the 4g63

 

[Spyder4g64]

How is the condition of the timing belt? You should always change the oil pump, water pump, and all timing belt components when getting a "JDM" motor.

My oil pump went on me, and after that experience with the "JDM" crap, I highly recomend doing so.

Did you perform a compression check on the motor? How are the numbers?

 

[TurboAnything]

you guys should be more careful when you post info. The EVOI-III are all 7-bolts. The 6-bolt with the cyclone manifold is a GVR4 engine it came with a small 16g. The EVOI-II came with the big16g and the EVOIII cam with yep the EVOIII 16g.

 

[Spyder4g64]

My motor came with a cyclone manifold, 510cc injectors, and an evoIII 16g (im 100% sure on the turbo). Also, it is a 6-bolt.

The motor was in a front clip, and the car was an early Evo. Possibly an EvoII? But why would i get an E3 16g on an EvoII?

There are many variants, possibly too many for me to account for, of the 4g63 overseas.

 

[sd_ff22]

1. Evo III motors came with a TD05H turbo, known as the evo III 16g, .
2. Cyclone Intake Manifolds
3. EvoIII = 6-bolt
4. 510cc Yellow Top Injectors
5. You bought a "mini-van" variant of the 4g63

evo3s did not come with the cyclone intake manifold.
I have an Evo3 IM and it is a bolt-on for 2g cars. the evo3 had a "similar" bottom end and a "similar" 2G head.
intake manifold is roughly 1/3 bigger plenum, 1/2 shorter runners, 52mm tb flange, no egr and no mdp.

and all

 

[Siral3x]

-EVO III was introduced in 1995 and it's a 7 BOLT!!!!;
-There is no such thing as a Cyclone intake on the EVO III!;
-TDO5-16G was stock, and 510cc injectors also;

Only the EVO I(all) and some EVO II had the same Cyclone intake and drivetrain as the GVR4!

 

[hopwoodp]

stickman- Where did you get your motor from?

Also, in case you guys don't know this, all USDM and JDM motors are the same. Year for year. The Evo 1-3 have larger intake plenums and throttle bodies and come with 16g turbos and larger injectors. Not much else is different.

Also, evo 1-3 motors don't have different compression pistons than 2g motors.

 

[Siral3x]

There are some evo III GSR with the optional RALLIART package very very rare...had a bigger fmic,some cool sideskirts, different gauges (280km/h speedo)...etc. I only saw one of those in UK...
I know for sure the cams are different in the EVO III then the 1g/2g motors!

 

[hopwoodp]

How so?

 

[Siral3x]

I had a pair of the evo III RS cams side by side with 1g/5sp cams and 2g cams...and the intake cam looked way diff then the other 2

 

[hopwoodp]

Can you describe that? Also, what is the evo cam lift and duration?

 

[Siral3x]

good point..I used to have a service manual for the evo 3 on a thumb drive...I will look it up!!! Sold them on ebay..I noticed the intake cam had bigger lobes.

 

[Siral3x]

http://www.evo-vi.com/evolution.htm
Best description of the evos period..

Looks like the motors were not the same either....

 

[TurboAnything]

Thank you for that link Siral3X there is alot of bad info going around. There are alot of JDM suppliers going around selling motors as EvoI-III when they are weak van engines. The Evo-III engine is a real good find for a 2g but you need to know what your looking for or you will get ripped off.

 

[hopwoodp]

http://www.evo-vi.com/evolution.htm
Best description of the evos period..

Looks like the motors were not the same either....

Your right. The Evo I-III motors were more like a 2g design than the 1g. Just like the 2g cams changed from the 1g design. The only thing I saw that was interesting was the compression ratio of the EVOIII engine.

Good find.

 

[Siral3x]

Ohh something funny to mention late 1994 and late 95 Hyundai Sonatas have 9.0:1 CR, 7 bolt, oil squirters, 1g head,1g mounts for engine, and 2g mounts for tranny. Engine bay looks almost identical with the EVO III, CR is the same, oil squirters....even the interior dash is simillar

 

[hopwoodp]

Funny. I heard from some where (not saying this is true) but, this person or site said that all jdm motors to include 95+ have 1g style oil squirters.

I don't know if anyone else ever heard of this. It actually goes against what has been said about the difference between jdm and usdm motors. I don't believe it and wouldn't unless I saw it.

You said EvoIII motors have 9:0.1 compression pistons? Would you happen to know the part number? And if the rods are similar to the 2g rods.

 

[stickman]

4G63 Motors typically go from $900 to $1400 including manifolds and turbo. Most will be 89-91 GVR-4 motors with a TDO5-14B turbo. You have a 20% chance of getting 91-93 motor with a 16G turbo. You have a 5% chance of getting a 91-93 RS version motor with the yellow bodied 510cc injectors and a Big 16G. It is very hard to tell for sure exactly what motor you will be getting. The best way to try to ascertain which it might be is to ask them to look at the turbo and the color of the injectors.

TDO4 (written on the compressor housing) Tiny turbo from an Auto Tranny car. Same motor, tiny turbo and manifold.

TDO5-14B: All the vanes on the compressor wheel will be the same size. Injectors will be blue (450cc).



http://www.roadraceengineering.com/4g63motorsearch.htm


As far as I know its the evoIII motor. I got it from Tiger Japanese Engines from Canadia.

I should have pulled the serial number off the block and cross-referenced it.




EVO Motors: The valve covers of the EVO 1-3 motors will be a kind of titanium color. They are the same as a US 2G motor with nothing fancy. They have the smaller 2G style intake ports, a small runner intake manifold with a larger plenum and a larger throttle body than a 2G motor. Still they are hard to find. Many are from other 4G63 powered cars and can have small 13G sized turbos. They will not bolt into a 1G because there are no provisions for the front roll stopper motor mounts that bolt to the block. Everything in Japan from 94 and up has the front and rear roll stopper motor mounts on the transmission 2G Eclipse style. Many people are running around yapping about how they have an EVO motor in their car. If it bolts into a 1G, it isn't an EVO motor

 

[hopwoodp]

4G63 Motors typically go from $900 to $1400 including manifolds and turbo. Most will be 89-91 GVR-4 motors with a TDO5-14B turbo. You have a 20% chance of getting 91-93 motor with a 16G turbo. You have a 5% chance of getting a 91-93 RS version motor with the yellow bodied 510cc injectors and a Big 16G. It is very hard to tell for sure exactly what motor you will be getting. The best way to try to ascertain which it might be is to ask them to look at the turbo and the color of the injectors.

TDO4 (written on the compressor housing) Tiny turbo from an Auto Tranny car. Same motor, tiny turbo and manifold.

TDO5-14B: All the vanes on the compressor wheel will be the same size. Injectors will be blue (450cc).



http://www.roadraceengineering.com/4g63motorsearch.htm


As far as I know its the evoIII motor. I got it from Tiger Japanese Engines from Canadia.

I should have pulled the serial number off the block and cross-referenced it.




EVO Motors: The valve covers of the EVO 1-3 motors will be a kind of titanium color. They are the same as a US 2G motor with nothing fancy. They have the smaller 2G style intake ports, a small runner intake manifold with a larger plenum and a larger throttle body than a 2G motor. Still they are hard to find. Many are from other 4G63 powered cars and can have small 13G sized turbos. They will not bolt into a 1G because there are no provisions for the front roll stopper motor mounts that bolt to the block. Everything in Japan from 94 and up has the front and rear roll stopper motor mounts on the transmission 2G Eclipse style. Many people are running around yapping about how they have an EVO motor in their car. If it bolts into a 1G, it isn't an EVO motor

I've known this for over 4 years. I can't even count how many times this has been posted. But, this is what we do know about JDM motors.

 

[Siral3x]

You said EvoIII motors have 9:0.1 compression pistons? Would you happen to know the part number? And if the rods are similar to the 2g rods.

I had a white 95 EVO III GSR four years ago, but since I moved to US I lost the service manuals...I can't find my usb stick! ;( I don't know the part number...BUT what I do know is that the 2.0L G4CP engine has the 9:0.1 CR, and 2G rods style. YES I have seen myself evo III rods and they are 2G style rods! I'm sure you can order a pair of pistons thru Hyundai, they are found in late 95 Sonata's.
I was reading not to long ago on this evo forum in Australia that the G4CP block(95+) is a replica of the 95/96 EVO III 4g63 block. Both are 7 bolt , 2g style rods, 9:0.1 CR, identical thermostat housing + you can bolt on 2G trannies to them. So indeed people that say they got evo III motors in their 1G are BSing.

 

[Siral3x]

Ohh..and one other thing is that the stock turbo on my EVO III GSR didn't have no TDO5H mark on it, it just had MHI 49178-01470 aka big 16G. EVO II have MHI 49178-01460, and EVO I - 01450. The 01470 has the 7cm housing, BUT early EVO III have the old 01460 turbos also: very rare!

 

[Siral3x]

49178-01010 - 14b ----MD138226
49178-01520 - Small 16G
49178-01420 - VR4-RS (yellow top 510cc RARE) aka big 16G --- MD168037
49178-01470 - EVO III BIG 16G (7cm housing) --- MR239345
49178-01460 = Evo 2 ( 6cm housing)
49178-01450 = Evo 1 (6cm housing)
49178-01400 /01410 = VR4 stock (came in 2 versions: 200hp or220)

 

[hopwoodp]

I had a white 95 EVO III GSR four years ago, but since I moved to US I lost the service manuals...I can't find my usb stick! ;( I don't know the part number...BUT what I do know is that the 2.0L G4CP engine has the 9:0.1 CR, and 2G rods style. YES I have seen myself evo III rods and they are 2G style rods! I'm sure you can order a pair of pistons thru Hyundai, they are found in late 95 Sonata's.
I was reading not to long ago on this evo forum in Australia that the G4CP block(95+) is a replica of the 95/96 EVO III 4g63 block. Both are 7 bolt , 2g style rods, 9:0.1 CR, identical thermostat housing + you can bolt on 2G trannies to them. So indeed people that say they got evo III motors in their 1G are BSing.

Where did you own your EvoIII? I don't believe the pistons you are talking about are for a turbo car.