Overhaul on the Galant VR-4
Well, project Phase I is complete. New engine, reworked engine bay and new suspension. At 132,000 miles, it was due for a few upgrades.
List of what I have done to the VR-4 recently. A list of parts and prices are included at the bottom.
- Rebuilt head (stock specifications) then exhaust side ported
- Was rebuilt a year ago during the ill-fated long block rebuild. New valves, guides and seats.
- Rebuilt and balanced short block with new crankshaft (stock specifications)
- When the engine seized, it was the number 1 cylinder. It spun the rod bearing on the crankshaft and locked up. This damaged the crank and bent the rod. So #1 got a new crankshaft and piston rod. At the same time I had all four cylinders honed and the block milled. Then, of course, had all new bearings, rings and seals put in.
- Removed balance shafts using Buschur kit
- This really seems like very little for $100. If you carefully press out the old bearings and press them back in
Take a hack saw and saw the oil pump stub off of the balance shaft
Well, BRs got to make a living somehow :-)
- Repainted the engine
- Block, oil pan and intake pipes are stove black (stove black is really cool hi-temp paint that has a kind of sparkle to it).
- Valve cover red like stock.
- Brushed the aluminum on theintake plenum, water neck and fuel rail.
- Replaced all vacuum hoses with silicon hose
- Miles of bright red hose in the engine bay :-)
- Walbro Hi-flow in-tank fuel pump
- Dont really need this much fuel flow, yet
- K&N air filter in the infamous swiss cheese air canister
- Removed air conditioning
- Is this what is meant by a hot car?
- 1990 oil filter housing with remote oil cooling
- Oil cooler pictures
- Got rid of the silly (and dangerous) water-cooled oil filter housing. In its place I put a stock 1990 T/E/L unit with AN-6 fittings to an external oil cooler. I used a finned cooler up front between the I/C and the radiator. The braided steel oil lines and nice Aeroquip fittings look very stylish.
- Porting pictures
- New 14b ported
- O.K., stop sputtering. I had to buy a new turbo a year ago and Satan got me for a factory 14b. Ill replace this with a 7cm 16g during Phase II. Did the porting myself for practice. The worse case was that I messed it up and had to upgrade now.
- New 1G exhaust housing ported and tapped for EGT
- See the comment for the 14b.
- O2 housing ported w/new O2 sensor
- Hallman boost controller
- They should just call this the Fun knob.
- Starion front mounted intercooler with 2.25 in/out ports
- Intercooler pictures
- Andre Santoso gave me this intercooler for free. It had a leak and a few damaged runners. Took this down to a show and had the leaks fixed for about $75 bucks. Thats pretty cheap for something that looks that cool under the bumper. Gave me just the excuse I needed to really lighten the bumper by removing most of the center metal to make room.
- 1g T/E/L intake plumbing
- Intake pictures
- Moving the battery to the trunk made room for T/E/L intake plumbing. It is much shorter and a straight shot from the MAS to the turbo. The stock VR-4 plumbing is twice as long and has four tight 90 degree bends in it.
- Replaced all of the seals
- Did the short shifter mod
- Shortened shifter pictures
- About half way from the old pin to the bend in the shifter. The throw is just about perfect, but there's just no way to get a DSM tranny to sift well.
- ACT street clutch
- ACT Clutch pictures
- I have the ACT copper metallic 4-button clutch. It would be killer to put that baby in. Literally! Cant imagine using that thing on the streets. Street clutch for now but maybe later
- ACT 2100 pressure plate
- I wimped out. I just really dont think I needed the 2600.
- 11lb ACT lightened flywheel
- Woohoo! Talk about quick revving.
Electrical and Gauges
- Battery relocation
- Battery relocation pictures
- Moved to welded bracket in trunk. Better weight distribution and more space up front.
- Power cable routed through interior to engine compartment
- VDO 30-25 Boost gauge
- Westach 700-1700 deg. EGT
- Jumptronix digital A/F and voltmeter
- This is a really nice digital A/F gauge. About 1.5 inches wide and backlite for night use. Very fast responding and doubles as a volt meter which is a absolute requirement for running big driving lights.
- Lotek A-piller dual gauge pod
- Although not a perfect match, a very close one. Material and texture are real close to the stock trim. Gauges fit perfectly, but the boost gauge brass hose fitting was a bit too long. I carefully measured where the fitting would be and bent it about 20 degrees. This worked perfectly.
- Newer stock GVR-4 springs
- Andre Santoso changed out his VR-4 springs at 70K miles. Mine had 120K miles. His were better.
- KYB AGX 4way/8way front/rear adjustable shocks
- $400! Cant beat this deal.
- Stainless steel brake lines
- Well, took a bit of work to get the correct rear lines from RRE. Mike did his very best, but finally had to fabricate new brackets for the rear to get the lines to work. I really dont care as long as they work, which they really, really do.
Tires and Wheels
- Stock wheels with Pirelli P6000
- Overall, not a bad tire choice.
- Eagle wheels with Bridgestone Blizzak
- Talk about traction on ice!
In no real order and some costs are guesses. I haven't bothered to include shipping, but it's around $100.00
|Item ||Cost ||Notes |
|Engine rebuild parts from Mitsu ||$ 361.00 ||Conicelli w/25% discount |
|Crankshaft ||$ 555.62 ||Toasted when the bearing went |
|#1 Connecting rod ||$ 66.20 ||Toasted when the bearing went |
|Engine block worked over, milled, honed ||$ 550.00 ||NAPA motorshop |
|Complete rebuild gasket set ||$ 120.00 ||NAPA |
|Carbide grinding bits (for porting) ||$ 120.00 ||Home Depot |
|Buschur Racing Balance Shaft Eliminator Kit ||$ 125.00 ||Buschur Racing |
|Silicon hose kit, red ||$ 38.00 ||RRE |
|Starion Intercooler ||$ - ||Thanks Andre! |
|Welding services ||$ 84.31 ||Morgan Motors and Marine |
|Hi-flow Walbro fuel pump ||$ 130.00 ||Tom Stangl |
|Hallman Manual Boost Controller ||$ 90.00 ||Buschur Racing |
|Engine O2 sensor ||$ 51.89 ||Conicelli w/25% discount |
|Remote oil filter and cooler ||$ 50.00 || |
|AN-6 fittings and braided oil hose ||$ 83.00 ||Summit |
|BG Syncroshift ||$ 30.00 ||Conicelli w/25% discount |
|K&N Filter Charger ||$ 45.00 ||Buschur Racing |
|ACT 2100 street clutch ||$ 260.64 ||Racing Concepts |
|ACT lightened and resurfaced flywheel ||$ 115.00 ||Advanced Clutch Tech |
|Braided clutch line ||$ 10.00 || |
|Battery relocated to trunk ||$ 35.00 || |
|Newish stock GVR-4 springs ||$ - ||Thanks Andre! |
|KYB AGX strut set ||$ 400.00 ||Mofugas Motorsports |
|Braided brake lines ||$ 99.00 ||RRE |
|Lotek dual gauge pod ||$ 40.00 ||Mofugas Motorsports |
|VDO Boost Gauge ||$ 55.00 ||RRE |
|Westach EGT gauge 700-1700 ||$ 35.00 || |
|TMO Datalogger ||$ 300.00 ||TechnoMotive |
|IBM Thinkpad and docking station ||$ 270.00 ||Bid off of the internet / for Datalogger |
|Subtotal ||$ 4,119.66 || |