What to replace when swapping an engine

[91TalonTSiCT]

I am putting another 4g63t into my 91 tsi awd bc i bent 7 exhaust valves on mine when the damn timing belt slipped...i dont want to talk about it...anyway, i am putting in a jdm that has about 38k miles on it and am wondering what i need to replace when i put the other motor in. i already checked vfaq.com and searched on here, but havent found a definitive answer.

which seals, parts, etc should i replace besides belts and motor mounts? i have an A/T that i need to unbolt off of one and put onto the other. do i need new gaskets? also, its going to have M/T injectors and cams. do i need any other computers or components for this to work properly? Thanks for any help ahead of time.

-Justin

 

[GVTalon]

Swap Tips

I just completed a swap, here is a quick list off the top off my head-

Starting with the intake manifold- Pull your US spec intake mani and TB assembly off as one unit and swap it with the JDM cyclone assembly. Check the metal gasket to make sure its good, if not replace it. (use your coil pack too)

Oil cooler- My JDM had an external oil cooler. The 91+ cars have a fluid cooled oil coolers. You will need to swap this from your US motor to the JDM motor. You should also get a new oil filter housing gasket.

Oil cooler water return line- You'll need this off your US spec engine too, its the metal pipe that runs up the front of the block.

Water Pipe- Again if you have an external oil cooler, you'll need the US water pipe that is fitted with the water nipple for the US oil cooler. You should replace the water pipe o-ring while you are there.

Thermostat housing. If it does not have a radiator cap on the top, you will need to swap the entire housing with US Spec as the lower half is different as well. You will need a new gasket here too.

Engine mount brackets- Put your US brackets on (the JDM engine I had didn't have brackets).

O2 Sensor. If you plan on using the JDM O2 housing, put your US spec O2 sensor in. You might want to consider porting the exhaust mani, turbo and O2 housing while its out of the car and easy to get to.

Use all the US spec sensors.

You SHOULD do a timing belt job. Also consider eliminating the balance shafts.

 

[Tevenor]

Originally posted by 91TalonTSiCT
I am putting another 4g63t into my 91 tsi awd bc i bent 7 exhaust valves on mine when the damn timing belt slipped...i dont want to talk about it...anyway, i am putting in a jdm that has about 38k miles on it and am wondering what i need to replace when i put the other motor in. i already checked vfaq.com and searched on here, but havent found a definitive answer.

which seals, parts, etc should i replace besides belts and motor mounts? i have an A/T that i need to unbolt off of one and put onto the other. do i need new gaskets? also, its going to have M/T injectors and cams. do i need any other computers or components for this to work properly? Thanks for any help ahead of time.

-Justin

Originally posted in the forum rules
Please use proper punctuation and grammar.

 

[AWDTsi007]

GVTalon,

Is the jdm cyclone turbo 4g63 motor a straight swap for a 96 Eagle Talon TSi AWD? Do you know where I can the specs for this motor?

Thanks.

 

[91TalonTSiCT]

Cyclone refers to the intake manifold that has dual runners that are sequenced to give more torque. The manifolds dont work without a few mods including a mod to open and close that second set of runners. Most people just swap the usdm intake mani onto the jdm when they buy them. The internals I think are the same except that the jdm MIGHT have some sort of forged piston. Also, the 96 is a 7-bolt. Most of the JDM motors I've seen are for 6-bolt applications. Depending on the money you want to spend, you can get a 7-bolt motor from either Pruven Performance or Slowboy Racing. Pruvens is about $2800 for a long block and I don't know how much Slowboy's are.

 

[AWDTsi007]

Originally posted by 91TalonTSiCT
Cyclone refers to the intake manifold that has dual runners that are sequenced to give more torque. The manifolds dont work without a few mods including a mod to open and close that second set of runners. Most people just swap the usdm intake mani onto the jdm when they buy them. The internals I think are the same except that the jdm MIGHT have some sort of forged piston. Also, the 96 is a 7-bolt. Most of the JDM motors I've seen are for 6-bolt applications. Depending on the money you want to spend, you can get a 7-bolt motor from either Pruven Performance or Slowboy Racing. Pruvens is about $2800 for a long block and I don't know how much Slowboy's are.

so that means that this 6-bolt will not work with my 7-bolt motor and I have to buy a 7-bolt motor, right?

Thanks

 

[91TalonTSiCT]

you got it. unless you want to go with a 6 bolt swap. if thats an option and you have the know-how and time to do it then vfaq.com has some info on that type of swap. im not too familiar with that whole process since im a 1g owner. For $1,900, you can get a tight short block from slowboy. A jdm long block runs about $1500 on average plus about $200 shipping and that's with usually around 35-40k on them. There are so many paths to choose, but they all have their own price range.

-Justin