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88 TSI CONQUEST 4G63 swap

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socjdqcer

10+ Year Contributor
46
0
Nov 9, 2010
Chicago, Illinois
Im getting ready to start my 4G63 and auto to 5speed build

When I finally have enough posts ill put this in the build section

This all started about a year ago when my brother bought a 88 TSI with a blown head gasket for $700. He bought it (not knowing anything about these cars) thinking it would be a quick fix. The plus side to the purchase was that the body of the car( except the faded clear coat and the paint coming off of the wing LOL) and interior were in MINT CONDITION! There is not a speck of rust anywhere and the interior is all original and looks like it just came off of the show room.

Well after he Failed miserably, I helped him replace the whole engine. The car runs fine, I drove it all weekend in fact!

Well on day my brother couldn't get it running and got sick of is just sitting so he GAVE it to me for FREE! After about 30 minutes of working on it I found out he had 2 spark plug wires crossed and since then it has ran great. He finally asked me how the car was going so i did the noble thing and told him the engine was shot! LOL ( I didn't want him taking it back!LOL)

Well here it is, I picked up the 4G63 motor for a great price. All i have to do now is get the Tranny. Im going to go with just a D50 trans for now, because My buddy has a D50 just sitting in his back yard so I'm getting it for next to nothing. The starquest is also a Auto so I'm going to take the challenge of turning it into a 5 speed.

Well Wish me luck! THE BUILD BEGINS!
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New motor all apart and now at the shop getting dipped
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this is everything that i took off of the 4G, ill figure out where it goes later LOL :thumb:
 
I dunno why you guys are suggest GM trannys... The good GM transmissions are autos and he clearly said 5 speed swap.

Anyways, good luck with the build. Love the starquests.
 
this is what i intended to do with mine before i decided to sell it. if i wouldnt of got the talon when i did my starion would of had a 4g in it instead of siting in my front yard for sale. i cant wait to see how this turns out there a blast to drive even in stock form
 
Any updates here dude?

I was following this build over at SQC also...
 
UPDATE UPDATE UPDATE HAHAHA, Sorry its been a while. Im a senior in college and this is my last semester so things have been crazy. The car has moved down on my priority list LOL. Well graduation is May 13 so it will really get rolling after that!

SO a few updates, Mortor is finally cleaned and i have been putting it together slowly but surely! I ended up just doing a stock motor rebuild, except for ARP Head and Rod studs. Ill post some pics. I was going to use a d50 or Mighty Max tranny ( not good for much power ) just to get the thing going, however plans have changed! BTW anyone want a stock manual transmission for a starquest!?

Bill Hincher ( Bell Housing God ) finally just finished making a 4G narrow block bell housing for the famous T5 WC tranny: Mustang T5 tranny to 4g54 in a Mighty Max - StarQuestClub.com - Page 2.
I love this tranny, plus they are a diamond dozen, so if it goes Boom Ill have a replacement the next day! I figured if i was going to do this build ill will just take my time and do it right!
 
I wanted to start a thread in the Build section, however last time i check, i wasnt aloud in that part of the forum yet LOL! Ill get some pics up for sure


BTW anyone need a stock 4g63 1G exhaust manifold? I dont need mine, Ill get rid of it for cheap! PM me!
 
If you need any help get ahold of Early Performance (Jared Early [email protected])

He had that 8 sec conquest that won the dsm shoot out two years ago. He built his from the ground up so he could help you with anything you need.
Good luck with school and the car!
 
If you need a pedal assembly for a statquest my brother has a few parts ones that he could get whatever you needed off of them.
 
Great build, and a very fun car indeed. I've had 3 of them.

I can give you some pointers on the 5 speed conversion, I did it to my last starquest:

Its easier to install the clutch pedal assembly if you remove the dash, and only takes about 15-20 mins.
You WILL NEED all the pedals from a 5 speed car, INCLUDING the gas pedal. If you use the auto gas pedal, it sits really close to the break pedal and is very impractical.
You will need to build or modify the cross member.
If you look under the hood where the master cylinder goes, you can actually see there is "template" for it. Take a long screw driver and hammer and start tapping inside the "template", and the metal on the inside of the firewall will start pushing back. With the dash out of the car, its way easier to do what is needed to get it out.
And finally, this is a important step, when you remove the clutch pedal assembly or whatever you will notice that the top bracket was tac welded to the firewall. I would STRONGLY recommend you tac weld it back, or rivet it. IF YOU DO NOT and you use a heavy duty clutch, your firewall will flex!

I hope all that helps you out.
 
Alright, Here is a quick update. I finally started putting the motor together and its going together nicely! It was a pain to put the HEAD together!
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Hey guys I need some help! My gasket kit didnt come with the Semi Circle Valve/Head grommet. any idea where i can get one. Autozone says I have to buy the whole kit... but i dont want to wait my money!
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Hey guys I need some help! My gasket kit didnt come with the Semi Circle Valve/Head grommet. any idea where i can get one. Autozone says I have to buy the whole kit... but i dont want to wait my money!

The part # is MD372348

STM: OEM MITSUBISHI HALF MOON VALVE COVER GASKET | 90-99 DSM | MD372348 $14.50 from STM

OEM DSM Half Moon Valve Cover Gasket - Extra Value Deals - DSM Performance Parts | DSMparts.com $6.95 from DSMparts

RTM Racing :: - DSM Turbo(4G63) :: OEM Mitsubishi :: Engine :: OEM Valve Cover "Half Moons" $15.51 from RTM

JNZ Tuning Online- OEM Mitsubishi Parts $12.58 from JNZ

Hope this helps!
 
Mercur Xr4ti / Ford Sierra cars used a T5 WC platform.

I have an XR4TI and a Starion ESI-R and I love both for completely different reasons........awesome cars that you don't see everyday.....Glad to see someone else is doing a swap to one....my project has been slowed a bit till I get a touch more expendable income but hey you know how that goes....good luck with it bro hope to see more of this thread......:hellyeah:
 
Alright guys so I ordered the Half moon shaped rubber grommit for the valve cover and i also ordered a new tensioner pulley and timing belt. I noticed though that in order to time this engine you need like a special tensioner tool. However, no one around here knows what it is and where to get one. Can i time the car with out one? Let me know, thanks!
 
Alright guys so I ordered the Half moon shaped rubber grommit for the valve cover and i also ordered a new tensioner pulley and timing belt. I noticed though that in order to time this engine you need like a special tensioner tool. However, no one around here knows what it is and where to get one. Can i time the car with out one? Let me know, thanks!

The tensioner tool is just to help apply the correct amount of tension. It is not required and in fact I have done several timing belt jobs and never used one. If you want to purchase it though check out Jay Racing or you can make your own, just get a 8" long 8mm x 1.25 threaded rod.

Timing Belt VFAQ Addition 1
http://www.dsmtuners.com/forums/newbie-forum/232328-timing-belt-tool.html
http://www.dsmtuners.com/forums/newbie-forum/145734-ideal-length-timing-belt-tool.html
http://www.vfaq.com/mods/timingbelt-1G.html
 
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