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.





I cleared the signals on the headlights, strut tower brace, SS air filter, SS adjustable radiator hose and flip-flop trunk modification.





Comparison of the factory mapping and NA changes.



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)


450cc/min Lucas high-impedance injectors, set on the right. The others are 335cc/min ($180)


OBX adjustable FPR set to 52psi ($86.00)


OBX enlarged fuel rail for 3G63t ($130)





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

A/R .48 turbine

38mm external wastegate 8.5lb spring ($100)


3G Eclipse turbo, tubular exhaust manifold ($130)



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)


Stock MAF adaptor ($20)


55mm blow off valve ($85)


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)



Hayden power steering cooler (tube and fin) ($50)


Hayden transmission cooler (bar and plate) ($50)


Oil catch can for valve cover vent ($35)


Mobil 1 full synthetic motor oil





Mechanical;

OBX adjustable cam sprocket ($75)


Upgraded breaks - cross drilled & slotted rotors with carbon metallic pads ($200)


Timing belt, balance shaft belt, all pulleys and tensioner bearings, I am missing one in the photo. ($120)


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)


APEX’i ITC ignition controller ($160)


APEX’i AVC boost controller ($310)


Turbo XS knock light, factory knock sensor ($120)



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



Exhaust;


High flow OBD II compliant catalyst (metallic catalyst) ($75)


2 ½ in piping ($150)
Thermo Tec exhaust wrap ($50)






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).




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.







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



Here are all the mapping changes for the turbo upgrade.




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.

What the… Mounting point, but no sensor?

There we go…


APEX’i ITC.


APEX’i AVC (boost controller).




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




Then the oil cooler and filter re-locator install.









Hayden transmission and power steering cooler installation.




Then the intercooler was mounted up.


After turbo install shots.





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.




Oil pan tap.



Turbo feed/return line.





Valve cover vent, oil catch can.


Installed!







Full view.








Now comes some body modifications.



New turbo system;
Hahn Racecraft Super 16G mounted to a Rev Hard EVO cast manifold.






Megan CF Muffler






APEX'i 1.3 kg/cm2 radiator cap.



CF Hood and Gas Lid.












PLX Wide-band AFR guage.



New PLX gear.


PLX Digital/Programable Guage (DM-100)


PLX IAT Sensor Module


PLX EGT Sensor Module


Juice, dry-cell style.


Some friends at a PA/DE/NJ meet.



MORE TO COME!

[JNZTuning]

Sweet build up man! I say 2.0 swap next.

[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.

[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]

Originally Posted by 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?

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]

Originally Posted by JNZTuning

Sweet build up man! I say 2.0 swap next.

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

Originally Posted by ray@turbotek

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.

Originally Posted by 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?

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.

Originally Posted by leg

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.

Originally Posted by CleanNeon98

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]

Originally Posted by 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

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. I have another one on the shopping list.

Sending the data to you.

[ray@turbotek]

ray@turbotektuning.com lets see what i can do

[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.