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SOHC to DOHC Conversion
If you are looking for 2.3/2.35 liter stroker info, here is a link for you.
Progress
January 2004 - first pictures
I purchased this car with 73,000 miles. It smokes occasionally when started, uses a little oil, has faded clear coat on the top, has torn axle seals, and runs great. The GLS package has power everything. Car $650
Vacuum/Boost gauge installed with hopes of fully using it someday. Parts $35 (purchased used for a previous car)
February 2004
The harmonic dampener pulley (crank pulley) gave out. The rubber in it had dried up and the two parts of the pulley separated. Stock replacement installed and works fine. Parts $150 (pulley + belts)
Installed new KYB shocks and struts. Part #s 235027 (front GR2 struts) KG9011 (rear Gas-A-Just shocks). Rides stiffer now. Still bounces more than I would like in the front. Definitely an improvement though. Parts $275
Dynoruns 1,2,3: You will need to install the DynoJet software to check out the raw data. I went in for a baseline test before upgrading. Roughly 85 horsepower and 115 torque (DynoJet "1.0" SAE climate correction factor and at the wheels. 102hp and 138tq at the flywheel if you use a 20% drivetrain loss.) It is running rich (12.2:1) and does not breath well (power starts dropping around 4,500RPM.) I purposely dyno tested it before completing all maintenance on the car. But the numbers are not too far from the stock Hyundai figures. Here are some pictures I made of the dyno graphs: HP, TQ, Air/Fuel
Purchased 1G turbo DSM (Mitsubishi Eclipse/Eagle Talon/Plymouth Laser) head off Internet. Screwed out of $150. Now own large boat anchor. The non-turbo throttle body might be usable.
Purchased 1G hard water pipe off E-bay. It cleaned up really nice. $35
Purchased 1G turbo DSM wiring harness in great shape off E-bay. $150
Purchased 1G turbo DSM ignition coil. $25
Purchased 1G turbo DSM oil pan off E-bay. Recieved a dented up piece of crap. Complaints don't go through on E-bay for this user??? Out $50
Purchased 1G turbo DSM fuel rail off E-bay. $35
Purchased 1G turbo DSM intake manifold off E-bay. $50
Already had a set of 450cc DSM injectors. Purchased previously for another car. $45
March 2004
Filled lower engine roll-stopper mount with Window Weld. While removing the engine mount, the bolts stripped and one of them broke in the lower engine support bar. The front two bolts for the engine support bar are also in bad shape. Lower engine support bar (Hyundai part 21700-33100) and radiator core support (Hyundai part 64100-33301) may need to be ordered to properly fix the problem. But it is working for now. There is no additional vibration inside the car because of the filled mounts and the rubberband feeling while accelerating is GONE. $15
Replaced the distributor cap and rotor (Hyundai parts 27110-21060 and 27131-32810.) It feels like there is some additional torque. Hopefully fuel milage will go up. $35
Purchased 1G turbo DSM cylinder head off of a friend. Has bent valves. He included a new set of exhaust valves. Turns out that the intake valves were also bent and all guides will be replaced. $200 used
Installed a PCV valve catch can. $15
April 2004
Started DOHC cylinder head conversion. Removing G4CS block to have machined. Including the engine and cylinder head rebuilds. $1047
Installing a Russell Clear Flow Fuel filter, 6AN fittings on the fuel rail and stainless steel braided fuel line to get rid of the stock (hard to get to) fuel filter. $35
Installing stronger engine mount/roll stop bolts. $5
Wiseco 8.8:1 forged pistons, ARP cylinder head studs, ARP rod bolts, ARP crankshaft main studs arrived. Will order Eagle H-beam rods this week. It is just not worth the risk running the stock rods. $650
May 2004
Received the Eagle forged steel H-beam connecting rods today. They are supposed to be good for 725 horsepower and come with ARP rod bolts. $380
Purchased an intake for a 1987-1992 Honda CRX for $28 shipped. For custom intake/intercooler piping to go with the 3" GM MAF.
Finished tearing apart the engine. Dropped the engine block and cylinder head off at Standard Machine in Glendale, AZ.
Picked up a window washer reserviour to start working on a cheap water injection system. $15
Purchased a Palm m105 PDA to eventually use for datalogging the ECU. $20
Purchased magnetic drain plugs for engine and transmission. $6
June 2004
Bought most of the required gaskets and the 4G64 DOHC timing belt parts from a friend. $130
Purchased timing belt hydraulic tensioner from Josh @ Conicelli Mitsubishi. $65
Purchased Cometic head gasket (87mm bore .043" thickness). $95.99
Picked up a shop manual. Working on the wiring harness and turbo ECU install. $45
Picked up a new oil dipstick and oil cap seal. $15
RAXLES AWD Eclipse Axles arrived! $450
Picked up engine block and cylinder head from Standard Machine.
Installed 3G (non-ticking) lifters, 2.4 DOHC timing belt gears. ~$180
July 2004
Working 6-7 days a week and it is too damn hot in Arizona!
Not much progress.
August 2004
Black Silicone vacuum lines. $40
Translab Shift Kit and new End Clutch friction plates. $35
Hyundai End Clutch o-rings, seals, and washer. $14
Teflon intake manifold gasket (basically a phonelic insulating gasket.) ~$15
Sent money for Translab drill bits. $6
September 2004
Translab drill bits came in.
Starting to have more free time again. Low on money this month. At least it is under 100°F.
Should have the last of the parts purchased in October and hopefully installed by months end.
Bought a slick, black DOHC valve cover off of a 1994-ish 2.0 Sonata. It is getting cleaned up and repainted. It uses studs instead of bolts to hold it on. But there are some bolts from a 1998 Sonata that we are going to try using.
Intake manifold glass bead blasted and will be painted the same color as the cylinder head. Traded for a friends, so now i have one that says "Cyclone" instead of "EFI-Multi". But it is not a true Cyclone intake manifold. Just a normal 1G from a JDM engine.
Received a turbo 1G oilpan and an extra ignition power igniter from a local DSM member.
Got the engine block and cylinder head painted with 1200 degree engine paint.
Interior is almost completely removed from the car. This is in an attempt to remove the engine wiring harness. The main problem is that this car is a converted right-hand-drive model. There is extra crap behind the dash that is not normally there. Wiring harness should be out by the end of the month.
Purchasing a 1G turbo throttle body from an old Mirage friend to make sure that I have options in case the 1G non-turbo throttle body sucks and does not work. These will also eventually get painted the same color as the cylinder head and intake manifold.
October
I got a new toy. Actually I got a running daily driver. A 1998 Eclipse GSX.
Painted a few more parts. Spent most of this month working on the GSX. Not enough money left to get the Sonata running before the end of the year.
November
1G throttle body came in. It was actually another non-turbo throttle body. So I'm just going to use it and get some mandrel bent piping to make the intake pipes.
Painted a few more parts.
Got a Road Race Engineering license plate frame. Woohoo :) No money to do anything else. Sorry this is taking so long...
Had to buy 2 tires for the GSX. :(
December 2004
Painted some more parts.
* Major items left at this point: finish installing the turbo wiring harness, purchase the oil pump, water pump, knock sensor, knock sensor wiring, finish assembling the engine, and put the interior back together.
I doubt that anything major will get done this month. Tis the month for buying crap for others.
January 2005
The wiring harness is out! We need to look at the Sonata manual and DSM manual to see what needs to be changed for the turbo wiring harness to work. After the wiring is finished, it is just waiting for the money to buy the last parts needed!
March 2005
Finally got some additional wiring diagrams. Labeled most of the connectors on both harnesses and started documenting what each wire does inside of a couple connectors.
I have been battling a knock issue in the 1998 GSX. Needless to say, it has me distracted. I believe the catalytic converter is clogged :(
May 2005
Getting closer. Most of the wire-tracing is completed. Just need to finish it and start combining/rebuilding the turbo wiring harness. Test fit it and then recover it in new wire looming!
Planning to install a 3" exhaust on the 1998 GSX early next month. So no big expenses for the Sonata right now. Hopefully in July. Atleast the wiring harness is cheap to work on.
June 2005
The Eclipse had a harmonic balancer failure. $200 down the drain for the parts and towing. The exhaust will have to wait another month.
The Eclipse is running a little hot on the freeway too, so another $50 for a new thermostat, radiator cap, and coolant.. Damn maintenance issues!
July 2005
Worked more on the wiring harness. Everytime I work on it there seems to be even more things that need to be traced and noted.
[Plans]
Stage 1 - Started
2.0 DOHC cylinder head swap/rebuild - Running Parts List
Stage 2 - 2006?
