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Project EVIL Tiburon 4G64 build

58K views 121 replies 35 participants last post by  Nexx896  
#1 · (Edited)
Latest build pictures are on instagram Romulus_6

This post for people who are interested in having Evo Lancer Engine swap in their Tiburon, more specific : 4g64 or G4JS 2.4L.

The Plan is to build an Evo Lancer powered, all wheel drive, Turbo charged Tiburon, with Evo manual transmission and drive train.

About my self.....

First off, my bad for the spelling i am from Russia, English is my second language. This swap is being done on my own, I do not have great deal of experience with turbo cars, I have done engine rebuilds on Fords and Hondas, just a small hobby of mine, so this should be interesting for the newbies. Since im a millennial, most of my info is being fed searching from the internet, so if u think I am missing something let me know.

I fell in love with this car from the day I played NFS Underground 2 even though I am an Evo Fan, I think the Tiburon looks gorgeous, its comfortable inside, the car handles very smooth, and jadajada... but the engine is a complete garbage, so here we go.... Let's change that....

My car is 06 Tiburon, automatic 4 speed, engine beta 2. With small mods to the engine, nothing serious, I had her since high school, lots of memories, the door is damaged but will be fixed later on.



Some info I found from Evo forums:

4G64

The longitudinal 4G64 is the second largest variant, at (2350 cc). Early models were 8-valve SOHC, but a later 16-valve SOHC and DOHC version was also produced. All used MPFI with an 86.5 mm bore and 100 mm stroke. The 4G64 was also available with gasoline direct injection. The version used in the Chrysler Sebring/Stratus coupes produced 152 hp (110 kW) at 5500 rpm with 162 ft·lbf (214 N·m) of torque at 4000 rpm. The Chrysler version features fracture-split forged powder metal connecting rods. The 4g64 is an interference motor like the 4g63.
Applications:

•1987–1990 Mitsubishi Sapporo
•1988–1990 Mitsubishi Van
•1990–1992 Mitsubishi L200
•1990–1996 Mitsubishi Mighty Max
•1993-1997 Mitsubishi Expo
•1994–2003 Mitsubishi Galant
•1996–1998 Mitsubishi Magna
•1994–2006 Mitsubishi Spacegear (2WD Version)
•1996–1999 Mitsubishi Eclipse Spyder GS
•2000–2005 Mitsubishi Eclipse RS & GS
•2003 Mitsubishi Outlander
•2005 Mitsubishi Zinger

Others:

•1989–1991 Hyundai Sonata
•1990–1992 Dodge Ram 50
•2001–2005 Chrysler Sebring coupe/Dodge Stratus coupe
•2004-present Brilliance BS6
•2008-present Chery V5


2.4

The large G4JS (also called the 2.4 D ) is the 2.4 L (2351 cc) engine. Engine dimensions are different from other Sirius blocks at 86.5 mm (bore) and 100 mm (stroke). Output is 149 hp (103 kW) at 5500 rpm with 157 ft.lbf (199 Nm) of torque at 3000 rpm. It has a cast iron engine block and aluminum DOHC cylinder heads. It uses MFI fuel injection, has 4 valves per cylinder and features forged steel connecting rods.
This Engine is no longer used by Hyundai

Here is the engine donor I pulled off a Jank yard, kia optima 04 126k miles, this is how it looks like in the engine bay. Unfortunately due to my laziness, I did not check the bearings before I bought the engine, I found out at home, that the crank was getting worn out, it looked like debris got in bearings and formed small guide lines on the journal and bearings, it has to be rebuild or buy a new crank, I probably will get a performance crank anyways, no big deal.



Little more about G4JS 2.4. Block is exact the same as 4g64, Head is like Evos, only with build in EGR, which I will close with a tap and a screw, also Intake manifold is bigger in size which has better air flow.




The block has all of the same features just like evo 4g64/4g63's
It has Oil squatters under each cylinder, which I know is very important for turbo vehicles, it cools off cylinders, great thing about this type of squatter they are not In a way of the pistons so they can not fail if something would hit them.

Block has 2 balancing shafts. One with for the pump, using gear ratios, and the other one direct hookup with sep timing belt. Balancing shafts fight nasty vibrations.
The crank is a stroker crank, 100mm stroke, unlike evos 88mm stroke. This is what I believe makes it 2.4L
Rods are forged rods, you can tell by a fat stripe on both sides of the rods, just like evos, these rods will handle a lot of HP.


It seems like gears could be swapped between Evos and Eclipses trannys, which is a good thing, if I want to go FWD route only.



Now for the transmission, if you want to keep auto, you can pull the whole engine with tranny from kia optima, its a direct fit, the brackets on the tranny are exact the same, but that would be lame, why do so much work to waste that power on auto tranny, here is the list of choices for the manual one, besides, you cant use Evo 8/9 ECU which I will talk about later.

There is a small list of choices of tyranny's on my list:
*2000 - 2005 3G Transmission FWD 5 Speed manual, direct fit and go, very cheap to find.
*99 and up Sonatas had 5 speed manual tranny too, really cheap choice as well.
*Mitsubishi Evolution 4-6 AWD transmissions is another way but little more expensive, were equipped with a diff case that is coming out a little below the axels, which should be clear underside of sub frame. This is what Libra Racing used in their all wheel drive Tiburon... The evo 4 - 6 T-Case based on my measurements, should sit right under front sub frame where steering is attached to.
*Mitsubishi 7-9 Transmissions would be the last of the choices, however the transfer case sits on the same height as axels, it would not work for awd on Tiburon because of that, unless you can bold up evo 4 T-Case, the only benefit would be the 5 gear on newer evos, they let you reach 175mph instead evo 4s 156mph. 5 gear can be upgraded on evo 4 transmissions for 250 bucks, plus they are cheaper to find than newer evos tranmsissions.

The Rear..............
Don't quote me on this yet, but the rear cross member can be swapped with AWD cross member from old AWD Tucsons, apparently they seem like having same design and same spot where the mounting holes are, which means this would leave us with 2 more questions left, what do we do with the fuel tank and where do we find a rear drive shaft. Well the fuel tank probably can be used from some other Hyundai Im hoping Tucson fuel tank would work, I haven't looked. But the driveshaft, might have to be custom made at some shop, I wouldn't think it would cost a lot.



I been working on the engine it self for these past weeks, cleaning and inspecting the parts. So far this is how much money I spent.

Junk Yard Parts:
G4JS Complete engine with no accessories and tranny - 385 - 75 core = $310.
Evo 9 used ecu: $60. Ebay.
Transmission with mounts - still in question, I can get evo 4 for $900 shipped.
Harness - from stock G4JS, $20.


Replacement parts and upgrades:
New Full Gasket set with Seal for everything you need, Head Bolts and Gray gasket maker: $69.98 Ebay.
New Belt Kit includes, Cam belt, Balance Belt, Water pump, 2 tensioners, Water Pump, idler bearing: $82.50 Ebay.
New aftermarket fuel rail purple color: $41.99 I dint like stock fuel rail it was plastic one with build in FPR.
New Timing belt cover: 14.10. Ebay
New Main Timing Cover: $55.00 Some other website.
New aftermarket Evo lancer engine mount $80.

Total cost so far: $1633.57, Engine only: $733.57, Transmission Evo 4 only: $900.
















Post Under Construction please be patient, thanks.
 
#3 · (Edited)
A AWD, Forced Induction Evo Engine Tiburon eh? I want to see this.

A high performance Tiburon is one thing, an AWD system is a whole new level. I hope you make this happen.
 
#4 ·
It would be cool to see this happen but you are going to have a hard time making it happen. If memory serves me right you are going to have a hard time fitting a driveshaft under the car. I can't remember what all is in the way but you will have to modify the car a good bit. Just throwing that out there.
 
#7 ·
You all are correct, it will be very difficult to do an AWD conversion, but if you can use parts from existing cars, good with your hands, and know how to weld, I do not see how this can be expensive, however my main concern as of now is just putting 4g64 with either evo 8 tranny with FWD only, or even more simple go for 3g transmission, all wheel drive is something I might try to do at the end..... I have seen pictures of some of the guys who have converted Tiburon to AWD, it did not involve rebuilding the whole frame, only the fuel tank had to be used from diff Hyundai because of drive shaft and the engineering of the whole rear chassis system was redone, but wel see.

I have went over to my junk yard yesterday and got my self one of them g4js engines of kia optima, I am very excited to start this project, but first I have to clean everything. I will keep you guys updated, thanks.
 
#8 ·
Can I ask, do you currently have the 4cyl or the V6 2.7 Tiburon? I also have the 2006 tiburon, 2.7 GT, automatic transmission. If like to keep the automatic transmission but i want more power. Is there a particular reason you chose that evo lancer engine other than the fact that it's a good fit? What makes this swap worthwhile?
 
#15 ·
I tore my engine apart, found out bad news about the crank it needs to be grinded, its getting too close to its limits, journal got small lines, all other parts in great shape, I think I will order my self a Forged Racing Crank for 600 bucks, more worth it than spending 300 on rebuilding the crank...

Still cleaning the rest of the parts out, ordered my self new cam covers, pump, belt, pulleys, bolts, gaskets, also evo 9 ecu, it can be flashed with evo 8 Rom as far as I been reading forums.

The engine mount seems to be off by an inch, I am planning on using evos mount and fabricate my own stainless steel bolt on mount on the frame, the mount for the engine on Tiburon looks ridiculous anyways.

I still need a harness, so I will hit my local junkyard and remove one from other 2.4 G4JS Kia Optima since, I wasn't planning to before, rewire it and put evo connectors, will be a lot cheaper... Evo used harnesses are 200 bucks at least, not worth it, I still will need to modify it....

Another thing I am missing is the transmission, as of now I am searching my cheapest options, thinking on getting evo 4 tranny and just remove rear transfer and put a plate over it for now, still need to research if it actually fits sub frame though...

After I figure all this out I will be left off with easy stuff, turbo choices, manifold, carburetor, turbo pipework, etc...
 
#16 · (Edited)
Sorry guys, haven't given any updates, got sick, Im in process of buying the evo transmission for now, I did not give up on the project. Just got my self a custom built 3 gauge pillar from Ortriz Customs, they did pretty good job, mached it to my white trim.
 

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#18 · (Edited)
So I ordered the transmission from eaby, here's are the pics they sent me before it was mailed. Wel see if it comes in one piece, its coming all they way from Canada to Florida lol.

Those damn ebay sellers, I had to bother them for quite a while to get the right price out of them.

No clue what are those pieces in the second picture though lol.

I demanded all the mounts, sensors and what not... they must have not fit the crate.

Other than that, my next steps is to continue cleaning up the block, while transmission is coming, once its here I will find some time to pull my engine out and see how this actually fits.
 

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#64 ·
No updates in almost a year and a half, although OP was on yesterday.
 
#24 · (Edited)
Havent got any updates yet. I got the evo 5 tranny and all needed parts, just got an issue with a motor on my civic, and it was my daily driver, Im replacing a block. For now I have to drive Tiburon, so I cant do anything with it until I get civic back up and running, stay tuned. Couple weeks ago I picked up a motor mount off 04 Gallant, it offsets pass side motor mount back to the center, like on beta 2, will help with the build. You guys wont believe how bad I want that engine in my tib with a nice turbo sound, oh man.....
 
#26 · (Edited)
While working on the block, I been doing some more digging considering all wheel drive feature, as I posted earlier regarding Tucson cross member fitment, unfortunately by looking at Tucson schematics it will not fit. However I started searching online different cars cross members and by looking at the set up I see Subaru's WRX Cross member, support beams etc match the same design as tiburons, now its obviously that the cross member wont be direct fit with ought drilling out new holes and offsetting the sides with some sort of spacers, it looks its possible to make it work with small mods to the cross member.
 

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#27 · (Edited)
And here is our tiburons cross member set up.... they look so similar......

So my plan for now is mounting the engine, get whole wrx cross member parts, and get a straight axel for real wheel drive and bolting all this on, and afterwards I will see what can be done with the fuel tank....
 

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