1991 Dodge Colt GL

A "domestic". I've changed my mind a few times, and now have my mind made up. Ugly, lightweight & AWD Turbo ~350hp.


1-owner. Very well taken care of.
Purchased 2005-09-16. Blown Rear Main Seal.
Built Sept. '90. 2174lbs (GVWR has 1000lbs added)
Doesn't hold oil. Still runs enough to drive it on the trailer.
Unassuming.
4-lug hubs, 13" wheels. Hubcaps. Power seat belts.
Straight 117,000 mile old chassis
I checked the lights, and I don't even need to replace a bulb.
Never even bumped. Straight as an arrow.
The side molding piece that fell off was inside on the floorboard.
75hp 1.5L 4g15 with 3-speed automatic. 27/29 city/hwy
Carpet sux, but everything else is there clean & complete.
Comfy.
Damn those automatic seat belts.
Complete interior. Lots of weight to lose.
filthy headliner
manual locks & windows
Oh it's a Dodge is it...? ' not fooling anyone.
October 29, 2005. Engine removal. Click link #10 to see video.
This is what was left when I was finished.
More stuff has to go, but not today.
Manual rack means I don't have to mess with the PS pump on the donor
Fortunately it leaked so much oil that it's not rusty.
Filthy doesn't suffice to describe it. ' date with a power washer.
Future home of intercooler pipes and a DOHC 2.0L turbo engine.
AC wiring & hardware, wiring harness, emissions stuff have 2 go.
Front end before swap modifications.
Stock front suspension and solid-rotor disc brake.
Before AWD front-knuckle swap
Stock springs have to go to make room for AWD stuff.
Stock rear suspension
Dinky rear drum brakes
Silly stock rear end.
This massive exhaust has already been thrown away.
Before gutting interior.
Bought the engine donor on 2005-09-10. Drove it home and it's STR...
The steering, body and suspension are worthless to me.
The engine, transmission, and wiring harness are great.
100% stock, 150,000 miles. It made it home without a hitch.
Check and pull engine 10-06-2005
It had a low #2 cylinder, but I know it's in the head.
It's $50 more for the whole engine gasket set than just the stem s...
So I'm taking it apart, seeing what's up, and freshen everything up.
Donor car #2: 1992 Eagle Talon TSi AWD
4-bolt Limited Slip rear differential.
K-member, axles, disc brakes
After a long break, stripping the Colt continues.
Suspension parts from Donor#2 and the Colt
Rear chassis stripped out, spare, tools, gas tank and rear removed.
Changed out the guts so the ECU will bolt into the factory location.
Replaced all the plastic hanger parts for a factory-looking install.
After turbo wiring harness install... clean.
Rewired the chassis harness and installed clutch pedal.
Removed everything, including the power seatbelts.
Installed a shifter, but need to replace it with a better 5-speed uni.
Changed out the perches on the suspension assemblies.
Big dual-vented rotors and 5-lug hubs.
Bolted on the car, needs camber adjustment.
AC stuff gone, emissions stuff removed. Engine harness installed.
Look at all this crap! JUST seatbelts. I weighed it.
Engine disassembly begins... Pistons look good! Need cleaning.
Main caps and crank look great!
150k old thrust bearing looks okay, but worn.
I'm replacing the bearings and rings for good measure.
Leading and trailing edges of the bores are worn from the piston skirt
Wear is typical for 150k, and even across all bores.
I honed it with 320grit stones & wire brushed the block's exte...
With all the loose stuff removed, it's time for hot-tank cleaning.
Close up of the honed cylinder bores. Fresh cross-hatches.
Balance shaft bearings knocked out to expose oil galleys.
Cleaned up timing cover, water pipe, front case, oil filter housing.
New OEM gasket set, and all new engine mounts to make the 4g63 fit...
New timing parts, water pump and all other rebuild parts.
I have some spare turbo parts from various Mitsubishi turbos.
7cm ported exhaust housing with 34mm wastegate flapper mod.
Stock 14b compressor housing.
look at the rough cast inside the collector
what do you think that rough cast does to the swirling air? Friction?
After 8 hours of grinding, sanding and polishing, this is what you get
How much friction is generated now? How much less heat?
Why is it that when you order a polished turbo, the do the outside?
Before and after shot...
Excellent condition 14b center section mounted to ported ex. housing.
Polished compressor cover. The wastegate actuator was ugly...
So I painted it. Hopefully these tricks will yield a few extra hp.