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 Post subject: vr4 conversion guide
PostPosted: Tue 10 Feb 2004, 12:04 pm 
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not sure where to start with this one but if everyone that has done the conversion can add some of there own info, i'll add it too this post and eventually we will have a guide :wink:

what parts you will need
cordia front and rear engine mounts
cordia flywheel
cordia starter motor
cordia gearbox
vr4 top engine mount
vr4 accelerator cable
cordia clutch
oil cooler

the old engine and gear box:

remove the radiator dissconnect the drive shafts exhaust and shift rods etc.

when removing your old engine all wires that are connected to the engine can be removed with the engine including most of the sensors on the fire wall you will need the ones that run from the starter and the reverse lights
and the ones that run to the wipers will have to be taken out off the loom

preparing the twin cam:

once the engine is out take off the front and rear engine mounts and refit them to the twin cam
remove the gearbox and flywheel have the fly wheel machined if neccesary you may have to grind off a locating pin on the twin cam crank where the flywheel bolts up
bolt up the cordia flywheel and the new clutch then bolt up the cordia gearbox and starter
remove the coil packs off the manifold as they will foul the fire wall

fitting the engine:

care fully lower the engine and g/box into the engine bay line up the 3 bolts for the gearbox mount but dont tighten them up yet
the front and rear engine mounts should line up all you will have to do is put the bolt back thru the centre of them
tighten up all the mounts
mount the coils some where
grind and reweld the top engine mount run vacuum to the gear box solenoid

getting there any comments welcome
i'll add to this later and also add pics if anyone took pictures of their convesion can they please email them to me

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Last edited by mrbishi on Tue 17 Feb 2004, 1:49 pm, edited 1 time in total.

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PostPosted: Tue 10 Feb 2004, 11:55 pm 
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thanks heaps for your input dude!! :D If anyone else has anything to add please do..

oh and if anyone wants to write up a step by step guide (like one of those haynes manuals) that would be awesome too!!

When i did an engine conversion on my pulsar i found the pulsar forums really helpful- mods should think about doing something like this: http://www.pulsar.org.au/tech.php

There is a section dedicated to turbo engine conversions with pics and helpful hints- http://www.pulsar.org.au/detswap/index.php

I know that seems alot but it would be a very useful tool for all who plan on doing the conversion- and it'l stop new guys like me asking stupid questions all the time hehe :lol:

Cheers
Mitch :D

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PostPosted: Sun 04 Apr 2004, 3:53 pm 
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First question, does the Cordia 5-speed have the strength to handle the output from a decently boosted VR4 motor? This is way more than twice the power. Should I go with a FWD gearbox from an eclipse or the like instead?

Secondly, it appears - from the manuals at least - that a Cordia gearbox may have the same bolt pattern as the DOHC VR4 blocks, however the bolts are 8mm and 10mm on the Cordia - while they are 10mm and 12mm on the DOHC. Is this actually the case, and if so is it a problem? Don't want to go shearing off bolts first time I drop clutch...


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PostPosted: Sat 22 May 2004, 2:43 pm 
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I'm not sure why u say coil packs hit firewall. Mine didn't.


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PostPosted: Sat 22 May 2004, 9:06 pm 
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Moved to the FAQ's - if anyone wishes to add anything, PM me.

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