mtcavity's 03 Galant 4G64T - New CF Hood (and ulgy winter rims)

[mtcavity]

Naturally Aspirated Galant,

Here are some pictures about a month after purchasing my G. I already got SSC 16” chrome rims with Hankook 205/55/16 tires, Tein S springs/camber correction kit F/R, Drilled/Slotted rotors carbon ceramic pads, OBX muffler, OBX header, K&N 4 ½” MAF adaptor/filter, and OBD II compliant, high flow ceramic catalyst.
http://i188.photobucket.com/albums/z274/mtcavity/GALANT010.jpg
http://i188.photobucket.com/albums/z274/mtcavity/GALANT011.jpg
http://i188.photobucket.com/albums/z274/mtcavity/GALANT012.jpg


I cleared the signals on the headlights, strut tower brace, SS air filter, SS adjustable radiator hose and flip-flop trunk modification.
http://i188.photobucket.com/albums/z274/mtcavity/galant030.jpg
http://i188.photobucket.com/albums/z274/mtcavity/galant028.jpg
http://i188.photobucket.com/albums/z274/mtcavity/2368044_73_full.jpg
http://i188.photobucket.com/albums/z274/mtcavity/2368044_74_full.jpg

Comparison of the factory mapping and NA changes.
http://i188.photobucket.com/albums/z274/mtcavity/2368044_59_full.jpg


PARTS (for turbo build)

Prices are included for referencing.

Fuel;

255/lph TRE performance fuel pump ($90)

Installed high amp relay and 14ga power supply wire for fuel pump ($15)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1016.jpg

450cc/min Lucas high-impedance injectors, set on the right. The others are 335cc/min ($180)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_53_full.jpg

OBX adjustable FPR set to 52psi ($86.00)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_64_full-1.jpg

OBX enlarged fuel rail for 3G63t ($130)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_55_full.jpg




Turbo;


I chose a smaller turbo for my build because of the nature of the 4G64 power band. Most of the power is derived from 2200 RPM – 5500 RPM, with a red-line of 6500. Stock HP is rated at 140 @ 5500, Torque (lb-ft) 155 @ 4000 RPM, out of a SOHC head with a bore and stroke of 3.41 X 3.94. Factory compression is just begging to be boosted of 9.0:1. Full boost is realized at 2400 RPM and can run up to 12psi steady, although I run it at around 9psi for day to day driving.

T3/T4 ($230)
A/R .42 compressor
http://i188.photobucket.com/albums/z274/mtcavity/2368044_31_full.jpg
A/R .48 turbine
http://i188.photobucket.com/albums/z274/mtcavity/2368044_35_full.jpg
38mm external wastegate 8.5lb spring ($100)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_50_full.jpg

3G Eclipse turbo, tubular exhaust manifold ($130)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_42_full.jpg
http://i188.photobucket.com/albums/z274/mtcavity/2368044_39_full.jpg

2 ½ in intake piping, 2 ½ in exhaust piping


Intercooler and intake;
6”x27”x2.5” bar and plate 3G Eclipse intercooler, 2.5” intercooler piping. The crappy couplers pictured here, not used. ($160)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_65_full.jpg

Stock MAF adaptor ($20)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1190.jpg

55mm blow off valve ($85)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_51_full.jpg

Silicone Intake Systems black, 5 ply, poly-reinforced couplings ($150)
NAPA high pressure hose clamps ($3.75 each x 12)




Lubrication and cooling systems;

Oil cooler and filter re-locator (bar and plate) ($180)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1035.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1036.jpg

Hayden power steering cooler (tube and fin) ($50)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1189.jpg

Hayden transmission cooler (bar and plate) ($50)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1101.jpg

Oil catch can for valve cover vent ($35)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1107.jpg

Mobil 1 full synthetic motor oil





Mechanical;

OBX adjustable cam sprocket ($75)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_47_full.jpg

Upgraded breaks - cross drilled & slotted rotors with carbon metallic pads ($200)
http://i188.photobucket.com/albums/z274/mtcavity/AUTOPICS002.jpg

Timing belt, balance shaft belt, all pulleys and tensioner bearings, I am missing one in the photo. ($120)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_30_full.jpg

Tein sport springs ($180)



Ignition system;

Autolite copper core spark plugs, one degree colder (3923), gaped to .29



Engine management;

If I could do it all over again, I would just have gotten E-Manage. APEX’i is pretty good stuff though, for the money.

APEX’i AFC NEO air/fuel controller ($280)
http://i188.photobucket.com/albums/z274/mtcavity/2368044_29_full.jpg

APEX’i ITC ignition controller ($160)
http://i188.photobucket.com/albums/z274/mtcavity/87_10.jpg

APEX’i AVC boost controller ($310)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1106.jpg

Turbo XS knock light, factory knock sensor ($120)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1037.jpg
http://i188.photobucket.com/albums/z274/mtcavity/2368044_81_full.jpg

ECU Flash/EVO Scan Data-logging ($90)



Exhaust;


High flow OBD II compliant catalyst (metallic catalyst) ($75)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1250.jpg

2 ½ in piping ($150)
Thermo Tec exhaust wrap ($50)
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1284-1.jpg





INSTALLATION

Installation took approximately 3 months of different phases of progression. With 100,000 miles on the G at this point there was some servicing to the engine needed before any boost is applied.

Service the engine was phase 1 where compression was checked, head was disassembled and gone over to make sure factory specs were maintained (done by my cousin Stacy Brown for those into local stock car racing). I changed the timing belt, balance shaft belt, all pulleys and tensioner, checked that the seals were not leaking at all on the cam or crank and finished up by cleaning the belt side of the motor. I replaced anything wearable on the steering and suspension (tie rods inner/outer, bushings and wheel studs).

http://i188.photobucket.com/albums/z274/mtcavity/HPIM1200.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1202.jpg

Phase 2 was fuel delivery upgrades and management installation. OBX fuel rail was “enlarged” to fit the injectors, along with upgraded fuel pump. Pressure is maintained through an OBX FPR. Injectors are Lucas 450cc/min, high-impedance injectors.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1003.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1015.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1022.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1024.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1026.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1034.jpg

Also the AFC NEO was installed, but not used until turbo was installed.

http://i188.photobucket.com/albums/z274/mtcavity/2368044_69_full.jpg

Here are all the mapping changes for the turbo upgrade.
http://i188.photobucket.com/albums/z274/mtcavity/ECUFlash-03Galant4G64TMapChanges12-.jpg



Phase 3 was ignition control and feedback installation. The Turbo XS knock light and knock sensor installation was necessary, no knock detection system was installed from factory.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1221.jpg
What the… Mounting point, but no sensor?
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1096.jpg
There we go…
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1099.jpg

APEX’i ITC.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1087.jpg

APEX’i AVC (boost controller).
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1222.jpg



Phase 4 is cooling devise installation, starting with the engine oil.

http://i188.photobucket.com/albums/z274/mtcavity/HPIM1042.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1043.jpg

Then the oil cooler and filter re-locator install.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1047.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1196.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1055.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1054.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1053.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1048.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1049.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1078.jpg

Hayden transmission and power steering cooler installation.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1228.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1230.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1231.jpg

Then the intercooler was mounted up.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1233.jpg

After turbo install shots.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1304.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1305.jpg



Phase 5 was turbo preparation; oil feed line, return line and oil pan tap, intercooler plumbing, exhaust plumbing, then final installation

Compressor view as I drill a hole for a tap to run a boost pressure line to the wastegate actuator controller.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1092.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1093.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1094.jpg

Oil pan tap.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1235.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1234.jpg

Turbo feed/return line.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1302.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1308.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1251.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1214.jpg

Valve cover vent, oil catch can.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1265.jpg

Installed!
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1262.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1261.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1271.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1284.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1285.jpg


Full view.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1279.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1283.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1282.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1281.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1280.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1287.jpg
http://i188.photobucket.com/albums/z274/mtcavity/Intercoolerfix.jpg

Now comes some body modifications.
http://i188.photobucket.com/albums/z274/mtcavity/trunk2.jpg


New turbo system;
Hahn Racecraft Super 16G mounted to a Rev Hard EVO cast manifold.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1386.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1385.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1387.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1384.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1388.jpg

Megan CF Muffler
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1409.jpg
http://i188.photobucket.com/albums/z274/mtcavity/CFMuffler1.jpg
http://i188.photobucket.com/albums/z274/mtcavity/CFMuffler2.jpg
http://i188.photobucket.com/albums/z274/mtcavity/CFMuffler4.jpg
http://i188.photobucket.com/albums/z274/mtcavity/CFMuffler3.jpg

APEX'i 1.3 kg/cm2 radiator cap.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1411.jpg
http://i188.photobucket.com/albums/z274/mtcavity/RadiatorCapInstalled.jpg

CF Hood and Gas Lid.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1469.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1465.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1471.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1473.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1474.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1475.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1476.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1477.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1478.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1479.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1480.jpg

PLX Wide-band AFR guage.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1458.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1481.jpg

New PLX gear.
http://i188.photobucket.com/albums/z274/mtcavity/PLX1.jpg

PLX Digital/Programable Guage (DM-100)
http://i188.photobucket.com/albums/z274/mtcavity/PLX2.jpg

PLX IAT Sensor Module
http://i188.photobucket.com/albums/z274/mtcavity/PLX4.jpg

PLX EGT Sensor Module
http://i188.photobucket.com/albums/z274/mtcavity/PLX3.jpg

Juice, dry-cell style.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1447.jpg

Some friends at a PA/DE/NJ meet.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1363.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1365.jpg

MORE TO COME!

[JNZTuning]

Sweet build up man! I say 2.0 swap next. :mrgreen:

[ray@turbotek]

very sweet build, i do have a question are you able to read and write yo this ecu successfully with ecu flash?

[Honest_Bob]

Nice! Looks like you did alot of research before putting this all together. Good job. :thumbup:

[turbo4g63]

great job! just one question....why a galant? If you had a dsm...do you know how much power you'd be making w/ this kinda time/money/modding done?

[leg]

nice write up. maybe you can help me put my turbo kit in if i ever decide to go booooost.

[CleanNeon98]

nice build...plan or replacing the wheels??

[AREA1320]

great job! just one question....why a galant? If you had a dsm...do you know how much power you'd be making w/ this kinda time/money/modding done?

with the parts that were chosen there doesnt seem to be much money involved. It seems like a budget build that went really really well.

I like it :D

[mtcavity]

Sweet build up man! I say 2.0 swap next. :mrgreen:

I’m taking “baby steps”, but I’ll get there.



very sweet build, i do have a question are you able to read and write yo this ecu successfully with ecu flash?

Yes, and will either be installing an EVO ECU, or repining my ECU and run the EVO 8 ROM (but will need the manual transmission). Mapping is limited on my stock ROM. I was able to tune in for 1-2psi of boost on stock ECU alone, and eliminate any "piggy-back tuning overcompenations", or tuning with piggybacks alone.



great job! just one question....why a galant? If you had a dsm...do you know how much power you'd be making w/ this kinda time/money/modding done?

I never intended on modifying this sedan, but here I am… I intend on getting into some real trouble in the future with later model DSM vehicles.



nice write up. maybe you can help me put my turbo kit in if i ever decide to go booooost.

Sure thing man! If you wait till summer, I should have a good grasp on TIG welding.



nice build...plan or replacing the wheels??

Yes, you are now looking at my winter rims! I planed to “bling-down” my ride with some sportier rims come summer. I was never a real fan of chrome, but they looked good when I just bought the car.



Thanks for the comments guys, this is the first vehicle that I went to this extent with modifications and my brain is still a little sore. Understanding the principals of engine management, turbo-charging, and general confidence building was the goal of my Galant. I do not see an end to my itch for tuning in the near or distant future.

[ray@turbotek]

that is so weird , is it because of the maf? you can only get 2 psi? also could you email me your rom , i want to play with something :)

[mtcavity]

that is so weird , is it because of the maf? you can only get 2 psi? also could you email me your rom , i want to play with something :)


Yes, and am too much of a sissy to changing the MAF or load scalings.

I have the EVO 8 translator and GM MAF, but I think I fried the translator while “probing” it more than I should have:o. I have another one on the shopping list.

Sending the data to you.

[ray@turbotek]

ray@turbotektuning.com lets see what i can do:mrgreen:

[ray@turbotek]

can you send it as a .bin or .hex file im unable to read this

[Mrjaydeeone]

looks good Corey. Welcome to tristate tuners

[mtcavity]

^^^ Naa Jay, Thank you for leading me to Tri-State-Tuners!:)

[Fastrick25]

Welcome to the sit and its good to see someone not afraid to do things slightly outside the norm.

[90Laser]

That thing is sick......winter wheels ftl though.

[4G64T]

Welcome bro..We deff gotta have another meet!..Love your journal

[mtcavity]

Thanks Ron, I'm keeping my eyes out but will probably be last minute due to the holiday scheduling. I need to go down to Langhorne again to pick up my wallet from Joe’s. I’ll set up a day we can meet down there.

[BillFromTR]

Awesome build up, how much power increase did you get? Those wheels gotta go, lol.

[mtcavity]

I work 12-14 hours every day through December (well not 23rd-25th), but I managed to get some work done on the Galant. If I had not, I probably would have gone postal and been thrown in jail...

CF Hood and Gas Lid.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1465.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1469.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1471.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1473.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1474.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1475.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1476.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1477.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1478.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1479.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1480.jpg
http://i188.photobucket.com/albums/z274/mtcavity/CFMuffler3.jpg
(it is black from the rich AFR I am running, it wipes right off)


PLX Wide-band AFR guage.
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1458.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1481.jpg

Got the spacer plate, turbo water lines, and had the turbo balanced (which is was already I found out).
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1463.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1422.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1423.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1424.jpg

Just waiting on the ARP, long, head to manifold studs. I purchaced 10 feet of Stainless 2 1/2 inch exhaust piping along with 2 U-J bends and 8 inch flex section. The exhaust will have 2 flanges so the entire exhaust will dissasemble into 3 sections. I am not sure what I want to do with the catalist. Maybe some of you can help me on that decision...

Tapped an oil return line for a friend on TGC. I cleaned (wire brush) the pan down, applied Rust Converter, then 3 coats of "Flameproof" high temprature, high durability (oil will not effect the paint) paint.

Anyone ever need something similar done, contact me.

Before -
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1430.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1432.jpg

After -
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1437.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1436.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1435.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1438.jpg
http://i188.photobucket.com/albums/z274/mtcavity/HPIM1439.jpg

I am looking into out-fitting my Galant with PLX Devise products. They have a new lineup of digital guages that is actually a monitor. I will be getting the IAT, EGT, Boost/Vaccum, Fluid temp, Oil Pressure, and the DM-200 OBDII/CAN
Intelligent Multi-Functional Display (iMFD). Check out their gear if you have 10-15 minutes.
http://www.plxdevices.com/index.html

[Laxinwarrior]

Hey ****er you never told me you were on here. :cool: Way to keep me updated too....:confused:

[mtcavity]

Jay (Mrjaydeeone), pointed this site out 11-7-07...

I'll punish myself with ice cream and pretzels for being such a rude SOB. :(


Here is another thing I forgot to speak to you about. Why the hell did you not call or stop by my actual house when you dropped off my wallet? :bigeek:

Wrench it day looked like it went well. (Would have gone better with Aqua Teen Hunger Force in the background). Sorry I could not come over and confuse everyone with my over-thinking.:lol:

I'll speak to you after the 25th, get some hang time with the OG crew.

PS - This is the guy who gave me a Hahn Racecraft Super 16G (needed rebuild) for free. I do owe him a quite a bit of wrench/tech time and better information about what's going down.:o

I'll get you a nice Christmas gift!:mrgreen:

[Mrjaydeeone]

Hey ****er you never told me you were on here. :cool: Way to keep me updated too....:confused:

Hey I didn't know you were here either

[mtcavity]

Hey I didn't know you were here either


WHAT?

Oh, so you want a X-Mas present and a wedding present?:bigeek:

How about my never ending admeration?:prayer:




Ok, a (small) gift it is...

[Mrjaydeeone]

WHAT?

Oh, so you want a X-Mas present and a wedding present?:bigeek:

How about my never ending admeration?:prayer:




Ok, a (small) gift it is...


haha thanks for the X-Mas present. But I am a Jew and Chanukah was the week before :rotfl:

[Honest_Bob]

Damn, I still gotta see this thing. :lol:

[CHAOS]

thats a pretty elaborate intstall man, looks like you know what youre doing... only thing i dont like is the wheels. the "chrome" ones i mean

[Laxinwarrior]

thats a pretty elaborate intstall man, looks like you know what youre doing... only thing i dont like is the wheels. the "chrome" ones i mean

Yeah we're working on those. :wink: Anyway, looks good Kory. Give me a call whenever you get a chance, I have some decent free time for a little while.