2.4 Liter G4CS Long Block and More Complete!

[Atuca]

Well I been cracking away at the build more silently lately, trying to knock this bad boy out! Well today I am a few accessories from completing the engine.

To catch you guys up, here are some pictures!

I worked on getting some of the accessories on the timing belt side while I was waiting for some assorted random oem parts to come in. One of the harder parts was taking my bag of bolts for the timing side of the engine and trying to match them up to where they go on the front case, ect.

View attachment 1637

Without some of the on order parts, I spent a few days filling time by cleaning the engine bay better, installing my FP 255 fuel pump, and cleaning random 6 bolt parts. With the help of my trusty dremel, I cleaned up some old gasket material to ensure a perfect seal on things like thermostat housing, intake manifold, rear main seal, ect.

The plan was to sand blast and powder coat almost everything on the engine; well I am over budget need to finish this up. This is going to be a race car, so I guess looks should be second to performance.

View attachment 1638

View attachment 1639

View attachment 1640

View attachment 1641


Part of the shipment came in, the non OEM stuff, which was just the spark plugs..... and the valve seals! I could finally finish my head and get it on the engine. I just following vfaq and used a sears valve spring compressor with socket cut out to get to retainers. I lapped the valves for like 3 hours, and assembled the head with the following parts:

Supertech Valve seals intake and exhaust
Evo 8 Valve springs
Topline 3G Lifters
Reused OEM valves and rockers
HKS 272/272

The half of the retaining clips going in was purely learning experience, and the second half of the head went much smoother by that time. They really are pretty tricky to get in there right. Pics!

View attachment 1642

View attachment 1643

View attachment 1644

View attachment 1645

View attachment 1646

View attachment 1647

View attachment 1648

View attachment 1649

View attachment 1650

View attachment 1651

View attachment 1652

View attachment 1653

Just for future reference, here are the holes that are blocked between the 1g head and the G4CS block. Everywhere I have read no one cares or drills them out. The one person I did see drill out the holes had nothing but problems having his HG seal, funny if you think about it

View attachment 1654

View attachment 1655

View attachment 1656

I didn't have the usual spot to thread my knock sensor into, so I used this spot above the A/C bracket between two cylinders.

View attachment 1657

And here it was after being torqued down with the ARP hardware. Sorry there isn't more in progress pictures, I been capturing this hole build via a HD camcorder

View attachment 1658

The next day I spent attaching the Intake manifold, 1G fuel rail, fabbing up my own EGR block off plate, and realizing the plug from the '90 Oil Filter Housing that I needed to remove to run oil to my turbo from it was a perfect fit into the hole in the upper Thermostat neck. Quick side note, I have an "extra" nipple on the bottom front of the thermostat housing, next to the bottom two sensors. Anyone know what thermostat housing I actually grabbed?


View attachment 1659

View attachment 1660

View attachment 1661

View attachment 1662

View attachment 1663

I'll save the next blog for setting the timing belt

 

[jjrock5]

Good progress man. I think I vaguely see red RTV on you OEM front balance shaft plug on the front case. i always recommend for ppl to use JB Weld on that area instead of the RTV because the pressure may cause the RTV/plug to pop out. The pics arent the greatest so I think it's RTV. Also, I do recommend gray RTV on the bolt that you placed where the old balance shaft tensioner pulley was. I cant tell if you did that either. It's looking great. Keep it up.

 

[Atuca]

I chose to use RTV instead of JBweld on the plug because research here on tuners showed the jb weld melting at that exact point there. Apparently jb weld has a pretty low melting point, but the high temp RTV I used should hold up great.

As for the bolt where the BS belt tensioner should go, I just used blue locktite so the bolt couldn't thread out. I did use RTV though all in the castle nut plug, dipped that washer/o-ring real good in it (didn't put any in the actual threading of the castle nut thread because of the bolt on the oil pump gear)

 

[gyd23]

lookin good!!
question, i bought my GSX with the G4CS swap already done and i need to replace the thermostat... i have the same neck as you but i don't know if its a sonata neck or 1g neck? (to determine whether to get a 180* 1G thermostat or sonata thermostat?)
thanks! keep up the good work.

 

[Atuca]

probably 6 months late, but it is a 1g neck sir.