1991 Galant VR-4 88/2000

[Dashnizzle]

This is the Build Thread for 1991 Galant VR-4 88/2000. Reply below.

 

[KCDsmDude]

Always excited to see another Galant.

 

[Dashnizzle]

More to Come !

 

[GST with PSI]

Always excited to see another Galant.

What he said

 

[Dashnizzle]

Finally got around to start wrenching on #88.

so far, here is what has been done:

- boost leak galore, had just about every IC coupler leak under 10psi, as well as throttle body, fuel injector insulators, etc.

just about all of the insulators looked like this:

To be expected with a 30 year old car might I add!
- swapped drive gears to a newer transfer case to keep the 22 spline the same as output shaft on tranny, new bearings and races.
- new hardware and billet bushings for driveshaft carrier bearings and rear diff plate and painted for rust protection.
-upgraded the MAF air cleaner with a plate that properly mounts a filter now with no leaks or missing hardware
- Cruise control delete
- purchased ECMlink, super excited to toy around.
-broke cam angle sensor adapter
-discovered extremely foul coolant with red flakes in FIAV valve

Lots more coming soon!
-Dash

 

[Dashnizzle]

 

[Dashnizzle]

Let the real work begin

 

[Dashnizzle]

Got some goodies and took apart the long block.

 

[Dashnizzle]

I’ve learned a lot about what this car has since my last post here. Turns out the motor is a JDM evo 0/RS motor from 1991/1992. This motor came from the factory with 510cc yellow injectors, a cyclone intake manifold and the pistons are stamped 68 DTR and came with a slightly larger turbo if I’m not mistaken. When the previous owner put this engine in the car, they swapped back to 450cc and a 14b turbo so the 510cc injectors were in a spare parts bin I found. The transmission in the car was NOT the evo/galant RS tranny that matches the motor since the Japanese version has a different final drive gear ratio. (3.9 or something like that)

I DO have the evo/galant rs tranny as a backup though and will be adapting it to this build! See below:
(sometimes the best parts you have are the ones in your spare parts bins, make sure you know what you have. I didn’t!)

Drivetrain progress:

Transmission - Evo/galant RS transmission is getting rebuilt for a final drive ratio of 3.545 matching the rest of the drivetrain, while keeping the taller gears. I think this will make gears 1-4 really close together and fun for unique spool as you shift gears with low/intermediate speed driving. Plus a long 5th gear for highway speeds.

Rear diff - completely rebuilt 4 bolt differential to replace 3 bolt.

All work done on tranny and diff by Jon at TRE. He’s the man.

I need 4 bolt rear axels now.


Bonus- just ordered the FP Green 57S UHF with xona rotor technology. YEAAAAA

 

[Dashnizzle]

Driveline parts on the way to Michigan to be rebuilt!

 

[Dashnizzle]

Rear Diff arrived!

 

[Dashnizzle]

Found another local VR4 in my small town of 60k people. He has been a huge help in build direction, especially suspension components.
The bushings on my rear upper control arms were toast so I decided to upgrade to a volk product. This shows how superior these products are when compared to this cast piece.

If you guys ever need to find the end links that connect the rear sway bar to the subframe you can use these ones I found on Amazon for $18 each:

Mevotech MS80812​

The FP Green UHF arrived and it looks amazing. Looks to me to be very similar to an old school FP red with the 8cm housing. FP claims that the UHF xona rotor turbine wheel makes up for the larger housing when compared to older versions. Can’t wait to try it out. Here she is:

 

[Dashnizzle]

Installed new OEM wheel bearings from JNZ tuning on both rear trailing arms. Installed stainless brake kit including new prop valve. ABS deleted. AWS almost all deleted minus the front rack fittings. Installing an AWS delete kit from 3sx once it arrives in the mail. Painted calipers installed new brake pads and rotors.

 

[Dashnizzle]

The 3SX AWS 3000gt delete kit bolted right up to the Galant with no problems. Kind of awesome to have a linkage in the rear to tie everything together replacing the deleted steering rack.

 

[Dashnizzle]

For anyone who may be following this, the JDM 'evo' tranny was pretty mangled up and not rebuildable due to the rare part cost and availability. Had to send in my backup transmission to TRE and we HOPE that one can get the treatment it needs.

Working on front wheel bearings, brake lines, rotors, and calipers next. Should have all 4 corners ready to go after this step.

After we get our stuff back from Jon at TRE, This will mark my completion of suspension, driveline, and brakes for this build. From here we will move onward to fuel and the much dreaded electrical. There's so many solenoids and wires that I don't know if I need.

More to come! Most importantly I am having a fun time and cant wait to get this thing on the road!

 

[Imback]

Always nice to see another galant coming along. Hope to see more updates.

 

[Dashnizzle]

MAJOR UPDATE:

Parts ordered and build plan finalized! Block purchased pre assembled and will be shipped this way!

BLOCK:
4G64 2.4 L from a Hyundai Sonata fitted with Wiseco pistons and H beam connecting rods. Pistons are coated for heat protection as well. This block from the Sonata was originally a 6 Bolt DOHC. This means it’s as simple as dropping your DSM head on.

HEAD:
All parts ordered:
- Kiggly beehives
- HKS 280’s intake and exhaust
-Supertech valves black nitride coated with all new guides keepers and all.
-adjustable cam gears

Once I have everything I am sending to the same machine shop AMS uses in Illinois to fit machine and assemble.

Can’t wait to drop it all in! Need to get everything on the car ready from electrical to fuel and all sensors sorted out etc. 2-3 months out at this point if all goes to plan.

 

[Dashnizzle]

Just got the rest of the parts needed for my head! HKS 280/280 Kiggly beehive springs, Supertech valves, guides etc.

Valve cover came back from the welding shop with my -8 AN fittings and wrinkle red powder coat finish it looks like money!!

Welds could have come out better but it sounds like the aluminum had a lot of impurity. Happy with results.

 

[Dashnizzle]

SUPER BIG UPDATE:
I added a flex fuel sticker please don’t flame me, I love it haha.

 

[Dashnizzle]

This part is soothing and very informational to me. The splices near the ECU junctions are from an old Apexi SAFCII that was spliced in. Couple cracked connectors but it should clean up well

So far I’ve deleted:
Fuel pressure solenoid
Cruise control connector
EGR stuff

Contemplating raychem sheathing but I don’t want to de-pin everything. Still looking into options for this one.

 

[1cleangsx]

Love the build. I bet that new GREEN will be a blast!

 

[Dashnizzle]

Love the build. I bet that new GREEN will be a blast!

Thanks! I think it will be a good spooler on this motor. Was told the 2.4L makes for ‘telepathic’ spool haha.

 

[Dashnizzle]

slow tedious progress on the harness. I got 5 rolls of TESA tape. This stuff is great. Need to wire up a few things and solder in CAS and TPS adapters when they get here. Overall everything was in really good shape so I got lucky.

 

[Dashnizzle]

The item 1991 Galant VR-4 88/2000 has been updated:

Parts list updated

 

[Dashnizzle]

Happy to report that the harness is wrapped and simplified a bit. Ready to go back in the car

Transfer case arrived. Thanks Jon!

Started messing with fuel