TECH : JDM Engines, Intake, Turbos, Clear out the misconceptions

[thilaksharma]

The main reason to post this up is to show that we over here do play with the 1st generation 4G63's , so we know more in depth about the VR4's and the EVO's
we have few thousand of engines , halfcuts and cars running on our land. There are
many , i really do mean MANY misconceptions and information about the JDM engines that has been stated on DSMTuners , although I have pin pointed some, but I guess you guys have your own beliefs, common ones are


Red Valve Cover engines, these are not EVO's , these are the Galant VR4 engines , they are similar to the 1G engines in the US , but there are some diffrences, VR4's have a 3 versions , VR4 200, VR4 220 , VR4 240 . The diffrence ? the VR4 200 and 220 comes with 450cc injectors and they have a td05 14b , Intake manifold for 200 and 220 is a Cyclone , VR4 240 is also called VR4RS from the E39A body , it has 510cc injectors , the healthiest vr4 engine to buy is the 4g63 VR4rs auto which comes with the td05 14b. vr4rs manual has td05 16g and a bigger intercooler. And if you notice properly on the VR4 200,220 doesnt have a diamond logo on its rocker cover, only the VR4RS and the evos have it. How do u diffrenciate a EVO 1,2 and 3 , its pretty simple, 3 ways , ECU , PISTON CODE , CHASSIS CODE and extra wirings at the firewall.

Here are the pictures of the intakes & rocker covers

VR4RS ECi MULTI Intake (Big Port)

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VR4 200,220 Cyclone Intake Manifold(Big Port) , VR4 200 Doesnt have the word "Intercooler" on it.

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Newer Generation 4G67 (Big Port)

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EVO I,II,III Intake Manifolds are all the same and so are the TB's/

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Heres the evo engine , this is a evo III , there is a vacuum grey cylinder on the firewall , its only on the EVO III's

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All EVO's have 609 Air Flow Sensors

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Intercoolers , the vr4's and evo's do not have same intercoolers.
The Vr4 200,200 has a smaller one compared to the VR4RS , the Vr4rs are smaller than the EVO 123, EVO 456 & 678 are totally diffrent.

VR4200,220 Intercooler

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EVO 1,2,3 Intercooler

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1800GSR Intercooler

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EVO 4,5,6 Intercooler End tanks face down

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Exhaust Manifolds , The EVO II and III are the best to last , this is because they are high in NI content and do not tend to crack. The VR4's are similar to the 1G exhaust manifold. The EVO manifold has an extra lump at the 1st runner if u notice. The EVO 4,5,6,7,8 do have a diffrent Exhaust manifold. What most users do not know is that
the they can fit the EVO45678 exhaust manifold & also its turbo to their 1G's and 2G's. Of cos the turbo will then face ## power steering pump or alternator, thats another issue.

VR4 Exhaust Manifold

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EVO Above , VR4 Below

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EVO 4 Manifold & VR4 Manifold

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[thilaksharma]

Engine :

All the vr4's have the same pistons and compression, they are codded 63DT.
EVO 1 & 2 has the same compression which is 8.5:1 which is same as 2g's
VR4's all have 7.8:1 compression which is same as 1G's.
EVO III has 9:1 compression. Code on top of pistons
EVO1 - H1
EVO2 - H2
EVO3 – EV

My vr4 engine that i just purchase ,

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All the vr4's have big ports like the 1G's . The evo's have smaller n wider ports like 2g's.
u can see the intake manifold port comparison over here

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(credits to ryan denke for this pic)
There is way to see if its a big port of a small port from the head , they have a cast marking on the side near the CAS , 2.0 is a big port , 1.8 is a 4g67 head , Evo's have diffrent markings.

EVO1 - G6K - 1 or 2
EVO 2 - G6K - 3
EVO 3 - G6K - 4 or 5


Turbo's

VR4RS and EVO1 has the same td05 small 16g while the evo2 has the td05 big 16g.
EVO III is a diffrent species. Somethings that I have experimented , the EVO 4-9 stock exhaust manifold will fit the 1g,2g 4G63 head , you can use their TD05HR , but the problem is the clearance issue with the alternator if its fitted in a DSM or EVO 1-3. Another engine is the RVR , RVR has a 4g63 with td04HL , i guess td04HL is not that common in US . td04HL is twin fin turbo and the turbine housing is nearly the size of the 14b 6cm housing. The o2 housing of a the td05 14b will fit the td04hl without mods.

Codes for turbo , EVO 1 - 45 , EVO 2 - 46 , EVO 3 - 47

EVO III Turbo

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Vr4 Turbo

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Top is EVO I turbo , below is a EVO III

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EVO III Turbo

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EVO III Turbine Housing

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EVO I Turbine Housing

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EVO 8 Turbo

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ECU's

as for Ecu's , all the evo's have different ecu's and mappings , the evo3 has less timing in it due to high compression. Don't get fooled by ecu's such as Mines and Ralliart, they are not worth it compared to your DSMLink. All evo ecu's have EPROM on it. But of course DSMlink isn't compatible with it.

vr4 200hp ECU 8618
vr4 220hp ECU 8618
vr4 240hp ECU 5818
E1 - 7701
E2 - 2468
E3 - 2364

Chassis Code:

EVO 1 --CD9A-SNGF
EVO 2 - CE9A-SNGF
EVO 3 - CE9A-SNGF


Injectors

Injector wise, guys, don't argue , we have few thousand cars over here, we cant be lying ,
VR4 200,220 Cyclones have 450cc injectors , VR4RS , Evo 1,2,3 have yellow 510cc injectors , EVO 6-8 have 560cc injectors , another easy upgrade is the RX7 denso injectors, they are 550cc. There are many people who do think the EVO3 has a 560cc injectors, it doesn't. 450cc VR4 injectors are blue in colour. 560cc injectors do have 560cc written beside their injectors. Physically , look at the injector nozzle of the 510cc Yellow injector, if it has twin nozzles its a evo, if its a single spray patern its the Vr4rs

Vr4RS 510cc injectors

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The EVO I

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The EVO III

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Throttle Body wise , the 1G has the 60mm over in the US, its cousin vr4 has only a 54mm Throttle while all the evo's do have 60mm TBs. Alternative TBs which are 60mm are Mitsubishi 6A11T and Mivec 4G92.

Drivetrain
VR4 gb's have the weakest 1st gear (this was even stated in Jack Transmissions)
EVO 1-3 have close ratio gearboxes. Cars that run 2wd over here usually go through a process where we throw away the extra gears & parts in the GB since we want to run 2wd only. EVO III comes stock with LSD at the rear.

Lately I opened up my evo III gb, it had something different in it, rather than the normal coupling, mine had one with an engrave which noted "Adelia Magic" , the picture is below, I contacted that Japanese company through email, what they have mentioned is that , the allen bolts can be removed from the coupling, there are two pieces of clutch inside and some adjustments can be made to it , these adjustments will determine the amount of torque i distribute between the rear and front wheels. Once the clutch inside it tends to slip, it will then feed the rear wheels. How true it is ? I am yet to find out.

My Adelia Magic Coupling

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Gearboxes codes (copy pasted):
W5M33-2-NGRE Lancer gsr RS (1992, 1800cc) ?
W5M33-2-NNZT Eclipse AWD 5spd mfg 3/94 ?
W5M33-2-NPXV 91-94 Eclipse AWD 5spd mfg 6/90-2/94 ?
W5M33-2-NPZT 95-96 Eclipse AWD 5spd mfg 3/94-6/96 ?
W5M33-2-NQBE Libero/Lancer Gsr, non lsd version of NRWE No 3.545
W5M33-2-NQBK 1991-92 to 4/92 VR4/ZR4 Galant ?
W5M33-2-NQBM 1992 Galant to 5/92 ?
W5M33-2-NRBE 92-95 Lancer GSR, lightweight synco's 2nd & 3rd No 3.545
W5M33-2-NRWE 92-95 Lancer GSR
W5M33-2-NRXD 1990 Cyborg No 3.545
W5M33-2-UPFE Evo3 RS with front LSD Yes 3.909
W5M33-2-UPGE Evo3 GSR non LSD No 3.909
W5M33-2-UPWE Evo3 GSR with front LSD Yes 3.909
W5M33-2-UPYE Evo3 RS non LSD No 3.909
W5M33-2-WPFE Evo2 RS with front LSD Yes 3.909
W5M33-2-WPGE Evo2 GSR non LSD No 3.909
W5M33-2-WPVF Galant VR4 E84A ?
W5M33-2-WPWE Evo2 GSR with front LSD Yes 3.909
W5M33-2-WPYE Evo2 RS non LSD No 3.909
W5M33-2-WQFE Evo1 RS with front LSD Yes 3.909
W5M33-2-WQFK Galant VR4 evo ? ?
W5M33-2-WQGE Evo1 GSR non LSD No 3.909
W5M33-2-WQNK VR4 Evo, close ratio box ? No 3.909
W5M33-2-WQWE Evo1 GSR (and RS?) with front LSD Yes 3.909
W5M33-2-WQYE Evo1 RS non LSD No 3.909

 

[thilaksharma]

Body of the EVO 1,2,3

evo I and II looks nearly the same, if its without the front LIP then its the EVO 1

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A EVO III Cut into two for sale, compare with the above pic , this is the EVO III

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Some Misc photos below , This is the LAND of JDMS , heaven

Need some twin plate clutches

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The Turbo World . OEM Turbos

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1JZ VVTI Single Turbo

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RB26

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R33 GTR RB26 + Greddy FMIC

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GTR Drivetrain

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Transmission Heaven, there are few more racks of these

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U want that tasty 4 pot brembo dont ya ?

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World of Suspensions , Cuso , Tanable , GAB , etc

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some halfcut being loaded to be taken away, ops notice on the left an evo
was chopped

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dear Hachi Roku RIP

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sweet heaven for the honda lovers

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a 4g67

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GTR r32 chopped

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evo7 in red , skyline in blue

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more evo's

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[thilaksharma]

some space for the future, pictures do not appear if i IMG tag them, i will find a solution

 

[360glitch]

Cool post. Embed the images and it'll be twice as cool. =)

 

[snowborder714]

A lot of your links don't work.

 

[tristanmb81]

half of the links does not work for me either.

 

[thilaksharma]

the links are all converted now

 

[360glitch]

the links are all converted now

Awesome, thanks man.

 

[tristanmb81]

you are the man! is that a junk yard? you should take off parts from those cars and sell them for a cheaper price.

 

[snowborder714]

I was just going to ask when I was going to get my first shipment of parts

 

[thilaksharma]

I was just going to ask when I was going to get my first shipment of parts

your shipment is soon
i will give u a JDM Evo3 , I want a talon

 

[thilaksharma]

you are the man! is that a junk yard? you should take off parts from those cars and sell them for a cheaper price.

it practically a junkyard , but the parts are all for sale , we have few hundred stores like this around the country

 

[brisvr4]

Nice info! Only thing that I might question is the VR4 intercooler. From the pic it looks like a std JDM cooler not an RS version. The RS version has 2 grooves in each end tank as seen on this page. And they are lot more 'squared off' than the stock unit.
Other than that nice work
$B%$%s%?!<%/!<%i!<8r49(B

 

[thilaksharma]

Nice info! Only thing that I might question is the VR4 intercooler. From the pic it looks like a std JDM cooler not an RS version. The RS version has 2 grooves in each end tank as seen on this page. And they are lot more 'squared off' than the stock unit.
Other than that nice work
$B%$%s%?!<%/!<%i!<8r49(B

my bad, fixed, will snap the RS pic when i get there again

 

[helluvadsm]

Old thread, but very good info! Subscribed! I wish I had your job! But I would probably be fired for stealing so many parts !

 

[nkosi]

thanks dude for this info on the vr4rs ...i manage to score a vr4rs engine here in montreal.....the importer didnt know what he had and i got it cheap. the engine is very strong and im about to upgrade to a fp dsm82 ball-bearing turbo .What about the cams the vr4rs comes with stock are they any different from the other engines.....

my bad, fixed, will snap the RS pic when i get there again

What about the cams the vr4rs comes with stock are they any different from the other engines.....