New Project. 1992 Eagle Summit AWD 4g63t *NEW PICS pg.2*

[Brett Haviland]

Well I have a new project on the go.

I recently picked up a 1992 Eagle Summit Wagon AWD project car.  This car is also known as the "Mitsubishi Expo" in the states I think, or the Mitsubishi RVR overseas.

Anyways originally the car came with a SOHC 2.4L 4g64 engine.  The previous owner (Kenta) swapped in a 1G DSM 6 bolt turbo engine with the 14b turbo  The transmission is from a Galant Vr4 turbo.   Im pretty sure the ratios with the VR4 tranny match up with the stock AWD summit rear end ratio (hopefully). He got everything almost done but ran into problems getting the engine running properly.  For whatever reason the car would start, but not stay running.  Now that I got the car I peeked under the dash at all the wiring and its pretty clustered and I dont really know where to start as he has a SAFC spliced into the wiring and shortened and extended wires all over the place.  Because the previous owner shortend all the injector/TB wires for a magnus intake mani, and now it has a stock 1G intake mani, all the wires are too short.  I figure since I should start from square one and install a spare 91-94 turbo DSM harness i have laying around and try and re-do all the wiring so I KNOW that its done right and installed properly.

If anyone knows any good information on these cars or wiring information or anything LET ME KNOW!!  Currently im trying to find as much information that I can to help with the wiring issues.

I will keep this thread updated as I progress with the project.  First thing is to get the engine running and the car movable under its own power.  Then i can finish installing all the interior pieces and get everything put back together.  

Here is some pics of the car





This shot is of the enginebay.  

And the Interior (in disaray and need final assembly and wiring clean up.)


Ill keep you guys updated once i can get this thing running under its own power.

HERE IS THE SPECS AND MOD LIST SO FAR

EXTERIOR
Smoke Black Front Bumper Turn Signal Covers, Front Turn Signals Deleted
Turn Signals Relocated, Bulb Upgraded to Dual Filament.
(Front turn signals relocated to corner lenses to increase blinker visibility from the side)

INTERIOR & ELECTRONICS
Complete A/C Removal, Condenser, Lines, Pump, Interior Unit, Wires, Brackets Removed
Custom Refinished Engine Harness – A/C, Cruise, California EGR Wires that lead to nowhere Removed
Wire Tuck, Wires Grouped Independently Per Sensor
Autometer Pro-Comp 52mm Boost Gauge
Eclipse Leather Steering Wheel with Mitsu Badging
Short Shifter Conversion – >50% Shorter Than Stock, New Shifter Base Bushings
25mm Lowered Steering Column mod

POWERTRAIN / ENGINE BAY
1992 6-Bolt 4G63T Engine, 130K
Rebuilt Galant VR4 Transmission, W5M33-NQBK with Taller 1st Gear
New VR4 Transfer Case
ACT 2600lb Clutch
8.5mm Spark Plug Wires
Walbro 255LPH HP (GSS-302) Fuel Pump
300ZX Fuel Filter
Autometer Fuel Pressure Gauge Installed In-Line
2G Exhaust Manifold
2G o2 Housing
Custom 3” Stainless Steel Turbo-Back Exhaust
Magnaflow 3” Muffler

SUSPENSION
Lowered on H&R Springs, Low km Talon Struts

[Andrew Brown]

super kick ass van man.  if i had the cash on hand i would have been all over that thing.

[Marke Bailey]

I got a spare harness that has been hacked some already, if you want to use it you can. I have done a bit of re wiring myself, so I can help if you need it.

[Brett Haviland]

Got it running tonight.

And thanks Marke for the help offer, but luckily i have a spare 91-94 5speed harness sitting in my garage

Luckily i was able to make the custom harness work after i trouble shooted it and figured out what was going on.

No more CEL and car is running better.  Still needs some finishing touches and intercooler/piping sorted out along with a BOV.  It also needs a throttle body gasket as it currently does not have one! lol.  haha

Heres some vids (might take awhile to become availible as i just posted them)
Sorry about the quality, i took them with my 4 year old crap cell phone, the audio is not horrible so it sounds cool at least lol.
http://videos.streetfire.net/video/This-is-my-92-Eagle-AWD_732399.htm
http://videos.streetfire.net/video/This-is-my-92-Eagle-AWD_732400.htm
http://videos.streetfire.net/video/This-is-my-92-Eagle-AWD_732401.htm
http://videos.streetfire.net/video/This-is-my-92-Eagle-AWD_732402.htm

Cant wait to get this thing on the road and driving around!

[Remi Raymond]

Brett pm me your cell. I'll be in maple ditch over the weekend. I have something you want, and I want to check this and your colt out.

[Brett Haviland]

Well i found out that the Van's use the same gear ratio's as the DSM's..  the automatics and 5-speeds have different ratios so you cant interchange the Auto and 5-speed drivetrains.

Looks like ill be swapping in a 5-speed DSM rear end or gearset somehow or someway!


*EDIT*

Phoned Kenta today and found out that the car was originally a 5-speed, not a auto like i though.  So that means i have the correct rear end ratio for my transmission woohoo

[Brett Haviland]

New pics posted on original post.

[Brett Haviland]

Well I got the Van driving and braking under its own power.  Finished up some of the wiring that needed to be soldered and cleaned up.  Also installed brake calipers and lines and bled the system only to find out there was no Brake shoes in the rear drivers side drum brake!  so obviously the wheel cylinder popped the piston out and leaked all the brake fluid out lol.  I just vice gripped the flex line a bit so keep it from leaking out anymore and then i was able to get a nice stiff pedal.  

Also fabbed up and modified the throttle cable to properly work with the 4g63 engine.  Now i can control the throttle from inside the car!! BONUS lol.

Drove the car backwards and forwards about 20 feet hahah...  

Still have to do the following things to get her safe to drive on roads.

-Replace both tie rod ends
-Replace front control arm bushings
-Replace drivers side ebrake cable and install rear brake shoes/hardware
-Finish installing the rest of the seats and various interior pieces and center console.
-Install SMIC/BOV and piping/mas/intake pipe
-Figure out where im going to mount the battery. (rear relocation or mount back in engine bay)
-Wrap and tuck away custom wiring harness under dash for ECU.
-Get a working Tachometer (stock 2.4L tach signal not same as 4g63 one)
-Hook up boost gauge
-Install wipers and washer sprayers


lol then she should be ready to put on the road and see what she can do!

Im off to pick-a-part tomorrow to see if i can get a ebrake cable and some rear brake parts!

Ill keep you guys updated

[Brett Haviland]

Well I got a bit of progress done on her this weekend. The drivetrain is all together now and the brakes are good to go. I changed out a bad lower control arm (bad bushings) on the summit van, also replaced a siezed front caliper and installed two new tie rod ends and a ripped steering rack boot.  Found all the parts I needed for the rear brakes and installed new shoes and ebrake cable.  Also I got the proper turbo outlet pipe I need, so now I can finish installing the intake and intercooler (stock dsm smic). Then all thats left is to make some sort of battery tray up, and put a cat on her and the rest of the interior together and take her through aircare so I can insure it, and drive it.

[Brett Haviland]

UPDATE!:

Well put a day permit on the Van today and took her for her maiden voyage with the 4g63t.  Went fairly good.  No major problems! Logged 160 km;s on her. 

Front wheel bearings are shot and make a hell of a racket when driving. No play in the bearings that i can feel but they sound like i have huge mud tires on the car lol.  Tried to get the car through aircare and it BARELY failed on C0's.  Will be putting a new cat in and trying again..  (suspect a bad cat was the issue)  Also need new front swaybar endlinks as those are making a ton of noise as well.

Overall tho the car/van thingy runs awesome!  Seems to be pretty good on gas so far as well and the drivetrain/rear end held up to some of my WOT pulls i did. 

Still have a few things to work out and replace and she should be on the road as my daily driver and ill be parking the 89 colt GT for awhile i guess.

[Constantin Morosan]

used to have one of these  but a plymouth colt one !! LOL oh good times !

[Brett Haviland]

hahah yup... they came as all kinds of names attached to them

some where plymouth colts, some dodge colts, some eagle summits, some mitsubishi expo's!!!!

[Constantin Morosan]

man i had some good times going an coming down for snowbaording with it .. OH do i ever miss that litle thing

[Brett Haviland]

well since i need money for a downpayment on a house i think this little van will be up for sale in the near future  

Anyways i got some more work done on the Van today.  Went to pick a part and grabbed some new knuckle and hub/bearing assemblies off the colt wagon they have there.  Luckily the bearings were in good shape!!  The ones i pulled off the van were in horrid shape, no wonder the made such horrible noise!!  I also replaced the sway bar end links with some new Beck Arnley ones as well and that really tightend everything up nicely.  no more wierd popping or banging noises from the suspension!  Went and took it for a quick drive and it drove 100% better with good wheel bearings and sway bar end links.... but the brake rotors that came with the hubs/knuckles were WARPED as hell... i was not stolked as the rotors were rusted to the hub BADLY!!!!   after some swearing and bashing with  a big hammer i got the old rotors free from the hubs and swapped over the other rotors i had that were in good shape.  I took it out for another boot and i was amazed how much like a stock family wagon/van it seemed to drive like!... besides the 3"  exhuast tone and loud whine from the walbro you would never know what lerks beneath the hood hahahahha.

[Constantin Morosan]

time to go eat some honda's LOL