1990 Galant GSX

[JG63]

This is the Build Thread for 1990 Galant GSX. Reply below.

 

[JG63]

Hello, this is another “It’s been awhile” story, but now I am back after about 8 years. I’ve had 6-7 DSM. my last DSM related car was a 240sx and I dropped in a 4G63. Unfortunately a number of things got in the way and I was forced it part it out. Definitely always think “what could have been.” It was setting up to be really fun car. I only ever ran, what I call the “spare tire turbo,” 14b. Great turbo because you can always find one and rely on it. It had the fuel support and mods to run much more. Anyways, on to the new project:

So I have always wanted a GVR4 but it was kind of a “fantasy” to me. (Even tho these days you can find a fairly clean one for $10k +/-.) But long story short wasn’t really looking for a car but I found this 1990 Galant GSX for sale. (The Galant GSX comes with a NA 4g63 from the factory and AWD / 3 bolt.) It had too many upgrades already and parts that came with it… that I couldn’t stop thinking about it. It was time to get another project. The previous owner (who builds motors for a living) rebuilt a stock 6 bolt turbo motor and put it into the GSX. He had too many projects going and was forced to sell. So to get it moving he put it back together and ran it NA.

At that point I picked it up with no miles on the motor and have basically just started cleaning it up. Doing the Free & cheap mods. Fixing leaks and looking over the wiring, setting timing, breaking it in more etc. Currently it has a Walboro 255 and no fuel pressure regulator, running NA, so you know it’s running rich. Waiting for the FPR to come in the mail this week. So that will be my first mod. Then doing the turbo swap. This motor tho starts up really well and runs great. Even running NA (7.8:1 comp) can feel a little peppiness and that its ready to be woken up.

My plans are to start with a 14b setup that I already have. Learn ECMlink with that. Only ever used premade chips. Then when I feel comfortable, do an upgrade to 20g or similar turbo. And see what happens. Basically have a poor mans GVR4. Keep it looking like a sleeper grandma car as possible.

The car came with a 1g AWD Turbo Transmission, Tcase, 4 Bolt rear end and axles. Currently running the NA 90 Galant transmission, which driving it I really like the gearing, but from what I have read it wont be able to hold torque as the boost gets turned up. I think only a couple of gears are different than the AWD. It came with a 91 AWD ECU with ECMlink (not sure version yet). 1000cc injectors. 2g MAF. 1g BOV. Intercooler (which I want to swap out to a different style). And a bunch of other parts.

These Galant VR4 and GSX are also known to rust, as many of you know, and this one has it all all 4 outside corners. So that is definitely on the list to fix.

Here is my tentative Project list:
* Fuel Pressure Regulator
* Clean Engine Bay
* Walboro is a little Loud so will check the Tank, Sock, Filter etc Possibly replace it.
* Buy a 1g or 2g Turbo AWD Downpipe
* Buy Electric Cutout (Turbo o2 housing -> Downpipe -> Cutout -> to Stock 2.25” Exhaust on the car)
* Complete the Turbo Swap:
* Install 14b Setup and Exhaust
* Keep the NA harness and Run Wiring: Knock sensor, Wire for MAF,
Wire in Resistor Pack, Swap ECU Pins to go from 90 to 91+ ECU
* Install Intercooler and Piping
* Buy Wideband o2 And typical Gauges. (Boost at the least)
* ECMlink setup and do some driving
* Start working on the Rust
* Swap out NA Trans and 3 bolt with Turbo trans and 4 Bolt
* Upgrade Turbo

At some point:
* 5 Lug and Big Brake swap
* New Wheels
* Paint the car (thinking of Plasti Dip and Plasti dip Clear coat but we’ll see when we get there)

 

[JG63]

Motor Build by previous owner and Pictures of the car.

Edit: Balance Shafts still installed on the rebuild. Is what it is for now.

 

[JG63]

Tidying up the Engine Bay. Before and after So far.

 

[JG63]

Installed my AFPR today. I was running the stock NA FPR since I bought the car. Took a chance… yeah.. with a Speedmaster AFPR. This one has -8 AN fittings for all three ports. There was a sale, figured I would try it. It actually seems to work really well. I have read a few threads that say a lot of the cheap or mid range Regulators have some sort of problem. Like the spring is too strong and won’t go below 40 psi etc. This one I installed, ran the 255 fuel pump and it went to 10 psi the way it came. Adjusted it up to stock NA fuel pressure and it actually held when I turned the Fuel Pump off.

I suppose I will really see how well it works when I get the turbo setup in and start tuning. Happy for now. Hopefully 2-3 weeks away from completing that. Just Time, Parts And money.








Edit: Resized Pictures

 

[JG63]

Update:
As usual, taking longer than expected. Not going to put any dates for completion anymore.

Mounted FMIC
Installed Turbo, Manifold, 3” Downpipe.
Installed 2g MAF
Ordered and received 1G to 2g MAF plug
Started my 3” exhaust mock up. Bought a 3” Stainless piping kit.

Needs a lot of Paint and cleanup. I will get it running then make it look better:

 

[JG63]

Soldered in Turbo MAF plug, Injector Resistor Pack, Knock Sensor Plug and installed Knock Sensor. Put in the 1000 cc’s. Turned the fuel pump on via ECMlink, no leaks! Pretty much have all the wires to the ECU. Just need to get some connectors to add wires to the ECU plugs. Also deleted all the EGR stuff off of the throttle body and got the block off plate installed.

Took the ISC sensor out and beat it like in Office Space when they beat down their printer. Not really, but pretty much done with having an ISC.

After that just need to do an oil change finish’s setting up ECMlink and start it up! once it’s running I will start taping up and wire looming all the cables then go get my exhaust welded up.

 

[JG63]

Finally Changed my oil. Tightened everything up. Plugged in the laptop and connected to ECMlink. Set it up with 2g MAF, global fuel and injector deadtime. Cranked the car a few times with plugs and injectors unplugged. Then I plugged everything in and it started up right away!

At first I thought the exhaust was just loud. It’s the Downpipe plus maybe a 3’ pipe connected. I still have to get the exhaust fitted and welded. (But I need to be able to drive to the shop) After letting it idle and checking for leaks I tried to drive away from my house but something didn’t feel right.

I start thinking is it the cheap 16g turbo, why did I put that one on should have just put the 14b on. But there was no smoke etc. I Notice in ECMlink I’m getting a code for the knock sensor… maybe that’s it… but I drive back and then the next day fixed that. I had taken the wires out of the connector and when I put them back they were backwards. So I fixed that.

Still just racking my brain is the engine good, I start thinking of the worst. So today I turn the car on and pull plugs. Pull Cylinder 1 car wants to die. Same for 2 & 3. Get to 4 and it makes no difference. But the wire is sparking. So then I pull the #4 injector, no change in idle. I start thinking is my wiring bad? I change the Red wire from the resistor pack to a different connection. Car starts and runs the same. Finally I’m thinking it must be the injector. So I move #4 to #3. Start the car Pull #4 first, car wants to die and goes to 2 cylinders. Pull #3 and no change.

So it’s a bad injector! So happy it’s not something worse or my wiring from the NA harness and wiring in all the turbo stuff! I even changed ECU’s, the PTU and other test but found the culprit. Makes me happy because it starts right up with 3 cylinders so it “seems” like it will be a good runner with the injector fixed. The injectors had come with the car when I bought it so wasn’t sure of their condition.

I bought an injector cleaner setup so we will see how that goes this weekend…. Hope for the best otherwise may have to take the injector, or all of them to be safe to a shop.

Huge sigh of relief!

 

[faqinshiet]

What you are in SD? I just shipped my to Virginia last year. here is a pic when it was last in San Diego.

 

[JG63]

What you are in SD? I just shipped my to Virginia last year. here is a pic when it was last in San Diego.

View attachment 730281

Barely missed me! Yes in SD. Loving your build.

Update Today got my new injector in the mail. Unfortunately had to fab it a little but it worked! Took the car around the block. Really needs the full exhaust.

Next step install Wideband then get the exhaust welded.

 

[faqinshiet]

Here is my vr4.org build https://www.galantvr4.org/threads/my-galant-gsx-build.33523/page-5#post-417621

 

[JG63]

Took the car out today. After replacing the one bad Injector the car is running great. Global fuel and Deadtime seem to be dialed in. Installed my Wideband and seems like it’s matching on ECMlink. (Grounded it at the same location as ECU as many threads have suggested)

Something to note as well is that my idle is rock solid on Cold start. Don’t even have to feather the throttle. And solid while driving in gear then putting the car in Neutral. I was worried that removing the ISC would give me trouble but nope.

You know you are a DSMr when your wife says: “I will go with you if you know it’s not going to break down or we aren’t going to get stuck.” (Too many bad past experiences with my projects I guess haha)

And of course it has been running driving on the freeway great on test and tunes. Then we drive today, her first time since the turbo swap, and I develop a coolant leak from what looks like at the Turbo. Despite the car drama, we made it back home.

So now my next step now since I’ve got it running. Now I am probably going to clean up the engine bay. Loom up all of the wiring. Paint some things. Find the leak and fix it. Also the Wastegate I have now doesn’t want to move at all so I haven’t been above 60% throttle. So I will replace that.

I cut the stock bumper, which I waited so long to do while I have been looking for a VR4 bumper. I really didn’t want to but… It doesn’t look AS bad as I thought it would. I am considering tying the bumper together with a front lip. Should make it look complete.

 

[faqinshiet]

fiesta island? that's awesome! my wife is scared of my galant.

 

[JG63]

Finally an update. The typical reason… life happens. Hurt my shoulder at work… don’t get me started with workers comp doctors…

I finally got my exhaust welded! Got the Homie hookup and got my stainless kit welded.




The car drives so much better. Before I was just driving with a Downpipe. All the rumbling was under the drivers seat. Now it’s a car I can just get in and drive.




So now since the swap is all complete I get to start fine tuning everything. Including fixing the dreaded corner rust spots. Painting things. Sanding things. Taping things. Looking at things. Making everything look better.
Baby steps…. Baby!



It was pretty cool today seeing a fellow DSMr while driving. (He was driving his truck) But he asked at the red light “is that a VR4.” I responded “I made it into one.” But that was cool, didn’t get his name but he said he had 3 DSM cars and is also on DSMtuners

Seems like the Knock off 16g is making some noise but it’s holding 20+ psi like a champ.

Also having troubles setting one of the outputs on ECMlink to control my fan. I have been trying to test the Fuel Pressure Solenoid or EGR output using the ‘gas’ pedal as a trigger, just to test it, But it’s not working.

Another observation is that the car starts up great without my ISC and holds idle rock solid. But when I push in the clutch while in high RPMs the car dies. (Clutch setup is Lightweight flywheel. 2100? Pressure plate and ACT Street disk.) Could just be the ISC delete but not sure. Something to look at.

Next steps is to get the Fan working by means of ECMlink. Fix little leaks from who knows where. Saw a bunch of things to button up when the car was on the lift while we did the exhaust. A big step I want to do is swap out the Non turbo trans for the Turbo trans and 4bolt setup that came with the car. Plus I am Having trouble shifting back into gear after hard pulls with the NA trans. Maybe bad (or just NA) Synchros? Not sure.

I also want to switch to E85 because 91 octane seems to be… no fun? a waste of time? Pick your reason? And E85 is accessible and so cheap down the street from where I am at.

That’s about it.

 

[JG63]

My friend kindly offered to make me a gauge bezel. I like the location where the clock is at so I gave him the clock and he used that as his starting design. Slides in and clicks right in place:

 

[JG63]

Update:

I swapped my Stock Galant GSX transmission, Transfer Case and Rear end setup. The Rear end now has 4 bolt Axles.

Driving it today for the first time it just feels stronger in general. I need to swap in the 91+ Shifter Assembly and Shift Cable Bracket that mounts to the trans. The only shifting issues I am having is getting into 1st and 2nd gear.

Another issue I am having is when at low speed, like slowing down and doing a U-Turn, the rear “locks up” and it feels like the car has a welded Dif. So the inside tire chirps. I don’t know the history of the Rear End but it seems to be fine at faster speeds. Something I am going to keep in mind.

I also changed my intake manifold, unfortunately not for function, but for looks. I had a “shaved” Manifold sitting around. So I painted it and threw it on. The previous manifold was a NA manifold so it didn’t have the second nipple for a boost source, so I suppose the swap was for function. But Now I have a small boost leak at the throttle body. So it is time for a BLT.

Another thing I did was Plasti-Dip the rear emblems, I feel like it came out good.

So overall I am happy with the car but shifting 1st and 2nd isn’t fun at all. So I am currently looking for the pieces I need to make the swap complete.

Below are pictures of the current setup. It still needs to be cleaned up, battery needs relocated etc. Also a picture of my custom exhaust.

 

[faqinshiet]

My friend kindly offered to make me a gauge bezel. I like the location where the clock is at so I gave him the clock and he used that as his starting design. Slides in and clicks right in place:

View attachment 737984View attachment 737985View attachment 737986View attachment 737987View attachment 737988View attachment 737989View attachment 737990

Is your friend selling these?

 

[JG63]

Is your friend selling these?

I will ask him.

 

[JG63]

Latest Update.

I relocated my battery. Swapped in the matching Shifter for the trans I just installed. Installed the matching shift cable brackets. I unfortunately I still am having troubles with 1st and 2nd. All other gears shift perfect.

When I shift to 1st it either doesn’t engage all the way or if I don’t hold it, it will pop out of gear. 2nd gear grinds every time. So now I feel like I am at a crossroads. *4 options I am thinking of:
1. Full Trans Rebuild
2. Partial Trans Rebuild to fix first and Second Gear
3. Buy a New (to me) Transmission
4. Go Auto (Feels very wrong )


So I haven’t driven it in awhile because it is quite the task and embarrassing trying to get it into 1st and 2nd. I have “Big” plans, switch to E85, SD etc. But first I need to take care of the trans.

 

[CrackedDSM]

If you don't absolutely live, eat, and breathe an auto DSM don't do it. That's coming from a die-hard Auto guy. You will never be satisfied with it.

If it's truly the transmission internals themselves that are bad, I'd say pull it out and attempt a rebuild yourself. Maybe buy a spare "good" trans in the meantime. If I recall correctly, there's a few good transmission deals out in CA on the DSM FB groups. One dude only wanted like $350 for the trans and tcase.

But I'd always worry about what went wrong with 1st and 2nd, and how much metal is in the transmission. Is it going to hurt something else? Just fixing the 1st and 2nd would have me worried that it'd get into other parts of the trans and hurt something else.


Plus I like to live vicariously through the guys with balls enough to rebuild their own manual transmissions, like @Anfurnyy .


Love this build though! The line about beating the ISC like the printer/copier in Office Space killed me.

 

[JG63]

On a side note I found pictures of a few of my previous DSM cars. I feel like Uncle Rico remembering the glory days… The ones that I let get away. The worst one I had to let go was my 4g63 swap 240sx. That car was going to be so cool…. Pictures for fun:

95 GST

92 6/4 Eagle Talon

1990 240sx “4g240”

 

[JG63]

If you don't absolutely live, eat, and breathe an auto DSM don't do it. That's coming from a die-hard Auto guy. You will never be satisfied with it.

If it's truly the transmission internals themselves that are bad, I'd say pull it out and attempt a rebuild yourself. Maybe buy a spare "good" trans in the meantime. If I recall correctly, there's a few good transmission deals out in CA on the DSM FB groups. One dude only wanted like $350 for the trans and tcase.

But I'd always worry about what went wrong with 1st and 2nd, and how much metal is in the transmission. Is it going to hurt something else? Just fixing the 1st and 2nd would have me worried that it'd get into other parts of the trans and hurt something else.


Plus I like to live vicariously through the guys with balls enough to rebuild their own manual transmissions, like @Anfurnyy .


Love this build though! The line about beating the ISC like the printer/copier in Office Space killed me.

Good points. I have a friend who says he can help. Makes me feel more confident taking it apart and it Sounds like he has access to the tools to do the job.

I have been doing the same watching the guys jump in and take their trans apart.

 

[Anfurnyy]

Good points. I have a friend who says he can help. Makes me feel more confident taking it apart and it Sounds like he has access to the tools to do the job.

I have been doing the same watching the guys jump in and take their trans apart.

There's a really good YouTube video on how to do it that I used. It seems daunting but once you get in it's actually more simple than you think.

Really all you need is a hydraulic press, and bearing splitter and some creativity.

 

[JG63]

I think that is the route I am going to take. Do the full rebuild not just do a cheap fix of the first two gears.

I am under the impression the Transmission is from a 91-92 AWD. But maybe I should just open it first then I will know what kit to buy?

 

[CrackedDSM]

I think that is the route I am going to take. Do the full rebuild not just do a cheap fix of the first two gears.

I am under the impression the Transmission is from a 91-92 AWD. But maybe I should just open it first then I will know what kit to buy?

I'd definitely learn from Anfurnyy's recent situation where he got the wrong year parts on accident.


Ya'll keep motivating me to try to rebuild a manual trans myself as well. Wonder how hard it is to modify 1st and 2nd for double synchros on a 90 trans.