1992 Eagle Summit AWD VAN. 4g63t swap. [Archive] - DSM Forums: Mitsubishi Eclipse, Plymouth Laser, and Eagle Talon Forum: DSMtalk.com

: 1992 Eagle Summit AWD VAN. 4g63t swap.

02-05-2010, 01:30 AM
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 pic is of another summit van... mine looks almost identical except it has painted bumpers

These are all from the actual car I own.

This shot is of the enginebay. It doesn't have the FMIC piping or the magnus intake or the afpr anymore as that stuff was not included in the trade i did for the car.

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


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)

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

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

Lowered on H&R Springs, Low km Talon Struts

02-05-2010, 07:07 AM
If you're competent and know your way around a 1g dsm wiring harness, I would just take that one out and fix it up with a solder gun and shrink wrap. Otherwise, it might not be a bad idea to swap harnesses. How long does it run before it dies?

02-05-2010, 12:33 PM
Got it running tonight. The SAFC was causing the ECU to not get a MAFS so i just reconnected it like stock and then it started getting MAFS. After that the car kept stalling. I found a ton of vac leaks so i fixed most of them and played with the BISS screw a bit and ended up getting the car to idle and not stall out. Still running VERY rough at idle. sounds like it has some high lift cams in it but im sure it doesn't. I then noticed that there is NO throttle body gasket inbetween the TB and IM so i guess i need one of those lol. Hopefully it will run a bit better after I fix that.

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
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.

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

02-05-2010, 08:20 PM
Dsm Van!!!!

02-07-2010, 02:01 AM
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 can't interchange the Auto and 5-speed drivetrains)

Looks like ill be swapping in a 5-speed DSM rear end or gearset somehow or someway so my final drive ratios on the front and rear diff match.

02-07-2010, 01:23 PM
Phoned the previous owner today and for some reason I thought the car was originally a automatic.

Turns out that it was originally a 5-speed car!!

Good news for me as that means my rear diff IS the right ratio!


02-07-2010, 04:08 PM
Good luck Brett. I hope you get some curtains for the windows and frequent the beach often when its dark :)

02-07-2010, 04:34 PM
Ahahahh "Creeper Van" in the making ;)

or maybe its the "Sleeper Van"

Some people might think it has a bed in the back and a camp stove if I call it that, lol.

02-07-2010, 05:21 PM
That thing is bad ass!!! I want one! Good luck with it man.

02-10-2010, 07:41 AM
Thats badass, I have always wanted to build one of these.

02-10-2010, 10:57 PM
wow. just wow, one of the coolest things I have seen in a long time, its like a massive AWD dodge colt! lol

02-10-2010, 11:11 PM

02-10-2010, 11:34 PM
You should run it open downpipe, so then when your driving around town everyone will look around wondering where the dsm is. :)

That's simply badass!! I wanna see that thing launch! :D

02-16-2010, 10:04 PM
Yeah I will definalty post up any progess I have on the car.

I got it running perfect, idles nice and smooth now and I had it hooked up to MMCD on my datalogger. Everything looks good to go!

Still have to install the front and rear seats, tidy/solder up some final wiring (hide engine bay wires), Install SMIC and piping/BOV, Finish screwing down and installing some of the interior plastics/trim. Oh also i have to buy new front rotors (Galant GSX rotors should work) and install my 1G single piston calipers.

After all that is done I will get some videos of it driving around and some better quality ones of it in some good light.

03-16-2010, 11:09 PM
Here is some new pics of the car. I couldn't edit the original post to update the pictures... so ill have to post them in a new reply. Here you go.

This shot is of the enginebay.
And the Interior (in disaray and need final assembly and wiring clean up.)

04-03-2010, 03:29 AM
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

04-03-2010, 09:28 AM
Are you going to run a intercooler?

TalonTSiAWD 723
04-03-2010, 03:41 PM
^ He said still has to put one in.

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

04-03-2010, 06:14 PM
Good catch! I suck at reading...

04-03-2010, 10:34 PM
I want one! Imagine beating a corvette in a damn van! The thought of it just tickles me inside. :D

04-21-2010, 12:13 AM
hehhe ill be sure to post vids of it doing so ;) ;)

05-01-2010, 10:56 PM
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.

06-16-2010, 10:49 PM

Well, I 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.

06-20-2010, 09:46 PM
Some pics I took yesterday. Its not washed and is dirty as heck, but I figure some pics couldn't hurt of the progress.


Hubbard 0
06-20-2010, 10:23 PM
Jesus, that thing is mint as can be. I'd love to find one of those and make it a sleeper.

06-21-2010, 01:25 AM
Wow... my brother drove an expo as his first car, jesus I didn't even realize this was possible until a few years ago. Nice to see someone building on one.

06-22-2010, 07:57 PM

Fixed a boost leak on my Van from the turbo outlet gasket. I also put a new 3" cat in the van to to get ready for aircare. I took it through and it PASSED!! yay!! hahaha

heres the results, not super clean but theres still a issue with what I think I've narrowed down to fuel pressure. I think the fuel pump isn't get enough power causing it to lean out under high load/boost situations.

But its passed! Good for another 2 years. Even tho the engine is from a 1991 talon tsi, the "van" had to do the IM240 test cuz (BC's smog test) the chassis is 1992.


vehicle reading / max allowable
HC / 0.4054 / 0.5000 / PASS
CO / 2.74 / 9.32 / PASS
NOx / 0.4589 / 1.2400 / PASS

a little high on the HC still, I think its running a tad rich still as I have a couple boost leaks from the throttle body shaft seals still.

10-16-2010, 01:37 AM

Brought the car out to Mission Raceway 1/4 mile tonight and did the following two passes

1st pass
14.3 @ 97MPH w 2.1 60'

2nd pass
13.7 @ 99 MPH w. 1.9 60'

car ran really good and im super happy with how it turned out.

first run was at 12PSI
second run was at 16 PSI.

MODS: Unported 14b, 450cc, 1G MAS, MBC, 3" exhuast, stock 1G DSM stuff mostly

Snot Rocket
10-16-2010, 05:17 AM
That would be a good pass for a stock DSM. So it makes me wonder what does that thing weigh?
Also is the stock rear axle a LSD a 3 or 4 bolt or what?

10-16-2010, 06:42 AM
That is badass!! Did you get videos of it?

10-17-2010, 12:01 AM
sorry guys, no vids. All i have is the timeslips.

not sure if the rear end is a 3 bolt or 4 bolt style.. Its not LSD tho, i know that.

THe rear axles are different then a 1G or 2G.... i would say more similar to a 2G if anything.

The wagon weighs in at 2730 lb's with no driver (rear bench seat and passenger seat removed)

10-17-2010, 12:17 AM
The wagon weighed in at 2730 lbs without the driver. This is minus the rear bench seat and passenger seat.

I think this van/wagon thing could easily be into the 12's with a few well placed mods. (FMIC, injectors, intake, tune)

Right now its on all stock DSM stuff.

10-17-2010, 01:16 PM
That's crazy man, those things are lighter than I thought. So really, how hard is the swap, or did you do it yourself?

This would be one hell of a sleeper, and a pretty cool family car for that matter. 4 doors, roomy, and quick as hell!

10-18-2010, 11:53 AM
Because its a 5-speed van originally it comes with the same rear end ratio as the 5-speed 1G dsms. A 1G engine will work fine and a GVR4 trans or 2G trans (have to mod shifter linkage tho and you might have to modify the rear mount on a 1G trans) will bolt directly in on a 92 summit/expo. the later years of the wagons i think you have to use a 2G awd style trans as the mounts are like a 2G, and not a 1G. You have to of course do the wiring on the harness to make everything work properly. That is the hard part of the swap. sorry that might be a bit confusing

I bought the car with the engine already swapped in it. The original owner could not get it running properly and thats where i stepped in.

01-26-2011, 11:05 AM
What is the word man. This van is a beast. No Updates in a few months.

Hows it coming along. Can't wait to see more progress. Fix the TB Gasket yet? Haha. Good Luck, Were all keeping an eye out.

04-27-2011, 11:07 PM
I sold the van... to a fellow local DSM club member. He is currently driving the van daily... He busted the timing belt on it and ended up putting on a built head instead...

i put on a smaller quieter 2.5" exhuast and got the interior all put back and completed... It was definalty a sleeper van, but also had the practicality of a wagon with the performance of the turbo 4g63 and the awd... i miss this van.