2003 Eclipse GT - 3.8L 6G75 MIVEC

Figured it has been a long time so I would put together a quick project thread over here. I have been getting asked about this by so many people and have been getting tons of positive feedback about it.

In 2014 I began the big project of converting from the stock 3.0L 6G72 engine to the 3.8L 6G75 MIVEC engine. I have spent quite a few years doing my research with this engine swap and have recently started finishing up this conversion. I will try to share as much information as I can, but if you have any questions please do not hesitate to ask!

From the beginning 2012-2014;

http://i228.photobucket.com/albums/e...h_DSC_0017.jpg http://i228.photobucket.com/albums/e...lipse26912.jpg http://i228.photobucket.com/albums/e...005_172515.jpg http://i228.photobucket.com/albums/e...64215766_o.jpg


NOW the good stuff 2014-Present - MIVEC Swap Begins

First draft of the 6G75 MIVEC Swap list can be found on the Tech page here;
http://blackheartmotors.weebly.com/tech.html

Required parts list -
6G74 Lower Intake Manifold – Gasket match lower flange to MIVEC gasket
6G74 Fuel Rails & 6G72/4 Fuel pressure regulator
6G72 Crankshaft Position Sensor w/Reluctor wheel
6G72 Distributor & BHM Distributor Mounting Plate
6G74 Power Steering bracket
6G74 Lower Timing Belt Cover
6G74 Alternator Bracket
6G72 A/C Compressor bracket
6G74 Coolant Housing & Sensors
6G72 Side Engine Mount bracket
MIVEC Patched ECU/PCM File or Separate MIVEC Controller


http://i228.photobucket.com/albums/e...76864274_o.jpg http://i228.photobucket.com/albums/e...76838875_o.jpg http://i228.photobucket.com/albums/e...76990660_n.jpg http://i228.photobucket.com/albums/e...116_091822.jpg
http://i228.photobucket.com/albums/e...907_155152.jpg http://i228.photobucket.com/albums/e...906_180639.jpg http://i228.photobucket.com/albums/e...907_161218.jpg


Port shaping 6G74 Lower intake manifold (we used this to be able to mount the return style fuel rails easily) The 6G74 and 6G75 MIVEC port shape at upper flange is identical, so only changes needed is a MIVEC gasket match to mate with the MIVEC cylinder head. More information of the MIVEC gasket matching can be found here; http://blackheartmotors.weebly.com/blog/thu-dec-25-2014

http://i228.photobucket.com/albums/e...08779374_n.jpg http://i228.photobucket.com/albums/e...27279003_n.jpg http://i228.photobucket.com/albums/e...222_075626.jpg http://i228.photobucket.com/albums/e...527_192853.jpg



Previous methods of this engine swap people were using the 6G75 MIVEC coolant crossover pipe. Doing this required cutting and welding the pieces to fit, and this required the distributor to be mounted in the front cylinder head versus the rear like OEM placement of the original engine (and 6G74 engine). Here you can see the Diamante 6G74 coolant crossover pipe assembly fitted and still allowing space for the distributor in the rear cylinder head (more detail on this below)

http://i228.photobucket.com/albums/e...528_130238.jpg http://i228.photobucket.com/albums/e...529_131408.jpg http://i228.photobucket.com/albums/e...608_075917.jpg http://i228.photobucket.com/albums/e...529_131353.jpg



Now for the distributor mounting location in the rear cylinder head to work, it took several months of designing a custom part. Due to MIVEC operation and oiling to the exhaust rocker shaft you simply could not make a spacer plate and stuff the distributor in place. This essentially duplicates the changes Mitsubishi made to these 6G75 MIVEC heads in late 08+ to only use one OCV (Oil Control Valve) to operate MIVEC functions in both cylinder heads. An oil supply line comes off the front OCV and feeds into the supply port in this plate.

I produce and sell this plate as a kit so that others can do this engine swap easily, those of you who were at Factory MOD 2015 this last summer may have seen the display stand of this part on a customer's 4.0L MIVEC swapped Eclipse (article here http://blackheartmotors.weebly.com/blog/the-flyby).

http://i228.photobucket.com/albums/e...313_191918.png http://i228.photobucket.com/albums/e...311_124145.png http://i228.photobucket.com/albums/e...620_220230.jpg http://i228.photobucket.com/albums/e...626_125141.jpg
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Here I am starting to get the engine harness sorted out and cleaned up. The fuse box has been removed from the engine bay and placed to the rear of the vehicle along with the battery (cosmetic preference).

http://i228.photobucket.com/albums/e...907_143311.jpg http://i228.photobucket.com/albums/e...907_163134.jpg



Now because I opted to use a modified 6G74 lower intake manifold, I was not able to use the 6G75 MIVEC upper intake manifold (flanges are different size between the 6G72/74/75 Non-MIVEC and MIVEC). This conversion still had to pass emissions testing as well so I am simply modifying the 6G75 MIVEC intake plenum to work with the Kia Sedona intake runners. This was done to retain EGR provisions on the plenum itself, ,and this will also increase plenum volume.

http://i228.photobucket.com/albums/e...907_160611.jpg http://i228.photobucket.com/albums/e...113_074640.jpg http://i228.photobucket.com/albums/e...118_082043.jpg http://i228.photobucket.com/albums/e...118_185757.jpg
http://i228.photobucket.com/albums/e...119_073602.jpg http://i228.photobucket.com/albums/e...117_131406.jpg http://i228.photobucket.com/albums/e...119_073657.jpg http://i228.photobucket.com/albums/e...120_071839.jpg
http://i228.photobucket.com/albums/e...119_102653.jpg


More updates will come, but this should be a good start on the project for you all to check out. For those that are curious about MIVEC control, it is being done via the OEM 3G ECU with a file made specifically for this (something I started working on back in 2012 actually). It will retain OEM function (duty cycle based) rather than just an "on-off" switch like others have done

Nice job, your thread doesn't disappoint!

Looks like your doing great things for the community, great work!

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Originally Posted by gtx

Nice job, your thread doesn't disappoint!

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it is pretty well compressed for all the work, but it shows the good stuff :045:

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Originally Posted by xd_01

Looks like your doing great things for the community, great work!

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The distributor plate is definitely a push in the right direction for the 3rd Gen Eclipse and 8th Gen Galant platforms. I am also working on some more projects as well which I hope to begin production stages of after the first of the year.

Updated the original post with more photos, details, and some helpful links

Awesome info on your project man! Questions, I'm assuming the 3G clutch and flywheel have to be used? Also, what year polyurethane motor mount inserts need to be used for a upgrade option? 3G?


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Quote:

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Originally Posted by 8gtorque

Awesome info on your project man! Questions, I'm assuming the 3G clutch and flywheel have to be used? Also, what year polyurethane motor mount inserts need to be used for a upgrade option? 3G?

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Yes, you would use an upgraded 3rd Gen clutch at the very least for this engine swap due to the increased hp/tq. The poly engine mount inserts would just need to be ordered per application (ie 3rd Gen).

Awesome. Thank you for all the info. I can't wait to start the project!


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These are the new "2016 model" distributor adapter plates. I worked on the design more for the cosmetics of the plate, logo is no longer covered upon installation, and the final product is even better than before :ndance:

http://i228.photobucket.com/albums/e...53709234_n.jpg http://i228.photobucket.com/albums/e...99707516_n.jpg http://i228.photobucket.com/albums/e...213_212031.jpg
http://i228.photobucket.com/albums/e...213_101928.jpg

Pictures are tiny.

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Originally Posted by oakrdrs187

Pictures are tiny.

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Click on them, they go big ;)

Last week I took some time off and spent a couple days finishing the modified 6G75 Non-MIVEC intake manifold. This has the EGR pipe flange removed, and the exhaust passage in the casting milled off. I cleaned the surface up to a light polish and then placed some DEI Cool Tape on the under side as some heat shielding.

I also modified the stock 72 Throttle body, cleaned up and mounted to the manifold. Yeah, some will question why the 72 TB, not a big deal. It's just to get running for the moment and I don't have to mess with this flange transplant and crap. I have a Q45 throttle body to replace it anyways.

I need to notch the hood brace and install this, then will be doing a quick fire up here shortly

http://i228.photobucket.com/albums/e...223_173845.jpg

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Clean swap, nice job with the tape on the manifold. Good idea

Startup video from yesterday
https://youtu.be/-NSjmrhjFcU

Here are some pictures from last week working on the car.

Installing the headers and getting cooling system filled up, these are a set long tube headers from Bj (boostezealot). I had to remove one of my cooling fans since it hit the header so I need to find some new ones...again lol....damn.
http://i228.photobucket.com/albums/e...231_090340.jpg
http://i228.photobucket.com/albums/e...090643_001.jpg

I need to get these installed yet too
http://i228.photobucket.com/albums/e...231_160644.jpg


Still working on the tuning stuff, but flashed a new ROM this morning and the car idles better than it did when I began a little tuning on Saturday.
http://i228.photobucket.com/albums/e...104_073558.jpg

What about 1 puller and 1 pusher fan to clear the header?

^ I was thinking the same exact thing. Awesome work man!


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Quote:

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Originally Posted by oakrdrs187

What about 1 puller and 1 pusher fan to clear the header?

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Quote:

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Originally Posted by 8gtorque

^ I was thinking the same exact thing. Awesome work man!

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I may do a pusher fan on that side of the radiator since its a tight fit there.

Still working on the tuning a little at a time, but here is another video of it running on a cold start up

https://www.youtube.com/embed/rR3pbpVLG80

I still had to extend the driver side headlight, fog light, parking light, and cooling fan wiring from the fuse box in the hatch up to the front accordingly. While doing this I cleaned up the routing a bit more and made progress down into the spare tire well. I still need to work out the mounting specifics in here, but I want it to be fairly clean when you lift the cover.

http://i228.photobucket.com/albums/e...109_181655.jpg

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With the cooling fan wiring up to the front I also needed to replace the fan on the driver side of the radiator. The motor no longer worked so I just installed the Derale fan that was on the passenger side. I believe I will add a pusher fan to the passenger side for the additional cooling. When the time comes to replace the radiator with a new one I will do two pusher fans on that change over.
http://i228.photobucket.com/albums/e...109_154107.jpg

I have not posted much for updates to the car for a while so time for a status update

The first day I fired up the car it turned over no problem and it was running well. After a few more times firing up the car and shutting it off I started having issues with the starter relay, then it failed so I just had to jump the starter to fire the motor up. At times the engine seemed difficult to crank over, I wrote this off as being due to battery relocation and cables not large enough and hooked up a jumper pack. Then a couple days later I have another issue that came up with a couple small ground wires that melted when I was trying to crank the motor over. So I needed to step up to some larger ground cables and installed a few more 4 gauge grounds and I no longer had an issue with wires melting, but the engine was still difficult to crank at times...Note to self, dont ignore a hard cranking issue

The car ultimately died on me one day on my way home for lunch and the motor was locked up. I tried turning the crank with a breaker bar and socket, but no go. It was time to pull the motor after driving it for a few short days and only about 20 miles of driving. A few people will wonder about the tune that the car had as well, but I can assure you there were no alarming knock counts leading up to this. I found two spots with 6 counts as the highest I logged and that was during first day of start up, I was extremely conservative with the tuning to start with so I didn't have to worry about high knock counts being an issue while driving to data log. I did not have an oil pressure gauge installed at the time (something being added now however), but given the condition of the motor when I tore it down it is fair to say the motor was not well maintained at all...my own fault for not doing a more thorough teardown/inspection.

Well, onto tear down photos

Pulled the plugs, all looked fine nothing smashed so i was happy besides the obvious running rich
http://i228.photobucket.com/albums/e...123_165011.jpg

Slowly disassembling the motor and checking things out. Once I got this on the engine stand I was able to break the crank free to rotate it around and you could feel where it was binding up and having that cranking issue...it was all making sense now.
http://i228.photobucket.com/albums/e...123_164440.jpg

Look at the oil sludge build up on this bottom end...5-6mm thick at least and was a bitch to clean up;
http://i228.photobucket.com/albums/e...123_160002.jpg


Here was the culprit issue;
http://i228.photobucket.com/albums/e...123_161718.jpg
http://i228.photobucket.com/albums/e...123_161706.jpg


Main bearings not so great from all the contaminated material;
http://i228.photobucket.com/albums/e...123_155930.jpg
http://i228.photobucket.com/albums/e...123_153254.jpg


Slowly cleaning things up and inspecting clearances and everything;
http://i228.photobucket.com/albums/e...129_201811.jpg


Checked the ring gaps on the piston rings that came out of the motor and these were the readings if anybody was interested;
http://i228.photobucket.com/albums/e...130_115704.jpg


Pistons didn't look bad, but they were all cleaned up a bit more and will be swapped to a new set of the stock 75 rods. I chose to use the stock rods vs 74s because I am only doing a basic short block refresh for this engine...a built motor will come later, right now I just want to drive this thing and enjoy it;
http://i228.photobucket.com/albums/e...130_115549.jpg
http://i228.photobucket.com/albums/e...131_112644.jpg
http://i228.photobucket.com/albums/e...202_114210.jpg



The oil pump needed to be gone through to inspect the damage. I really didn't want to buy a new oil pump so I just cleaned this up and checked the clearances, besides the obvious visual signs of wear this thing still checked out well within specifications. Since I will also be installing an oil pressure gauge this time around I am not real worried about re-using this pump either.
http://i228.photobucket.com/albums/e...130_141408.jpg
http://i228.photobucket.com/albums/e...130_135816.jpg


Now since the crankshaft needed to be machined and repaired I contacted Mile High Crankshafts out here in Denver to inquire about the repair and additional machining. With the one journal to be repaired and having the crankshaft nitride coated again to bring it back to OEM specs it would have been a $500+ repair bill. Fortunately I was offered a deal on a good used crankshaft so I picked that up and will just save the other crank for another engine built later
http://i228.photobucket.com/albums/e...203_162129.jpg
http://i228.photobucket.com/albums/e...204_075722.jpg



I cleaned up the engine block a little more, honed the the cylinders, and repainted the block with a wrinkle black paint which I am happy with how it came out.
http://i228.photobucket.com/albums/e...208_173809.jpg
http://i228.photobucket.com/albums/e...208_173925.jpg
http://i228.photobucket.com/albums/e...208_173946.jpg





I am slowly working on the reassembly, just waiting for bearings and piston rings to come in so I can get going on putting things back together again. As much as it sucked to have the engine crap out, I am glad that it happened now and now during a trip.

- - - Updated - - -

Another batch of the Distributor Adapter plates done, already sold 3 from this batch which puts us up to 8 MIVEC swaps out there as of now.
http://i228.photobucket.com/albums/e...213_150039.jpg

^ I'll be ordering this within the next few weeks!!


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Great Job This is Passion I tell ya Great to see people dedicated with there projects keep up the good work mate! Props!

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Originally Posted by 8gtorque

^ I'll be ordering this within the next few weeks!!

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Sounds good, I saw your order for the lower manifold come through last week as well so I will shoot you an email on that shortly

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Originally Posted by SPD_FRK

Sounds good, I saw your order for the lower manifold come through last week as well so I will shoot you an email on that shortly

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Awesome, I can't wait to receive it. You can contact me on Instagram. It will be easier to reach me.

Please send me the email asap on information statues update. [email protected] thank you


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People ask once in a while about the difference between the Non-MIVEC and MIVEC pistons so figured I would share a couple pictures of those side by side for people to visualize.
http://i228.photobucket.com/albums/e...311_180729.jpghttp://i228.photobucket.com/albums/e...311_180757.jpg


Making some progress with the short block, taking my time mainly. All parts/gaskets are here and getting it together at least at this point. Here I am polishing the bearings to final fit for oil clearances
http://i228.photobucket.com/albums/e...323_143657.jpg
http://i228.photobucket.com/albums/e...323_143849.jpg
http://i228.photobucket.com/albums/e...323_153158.jpg
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Setting up the Plasti-Gauge
http://i228.photobucket.com/albums/e...323_135036.jpg
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Final assembly for the crankshaft, heavy on the assembly lube
http://i228.photobucket.com/albums/e...323_153435.jpg
http://i228.photobucket.com/albums/e...323_153657.jpg
http://i228.photobucket.com/albums/e...323_154559.jpg


Next up working on putting together the rods and pistons, and checking ring gaps.
http://i228.photobucket.com/albums/e...327_154924.jpg
http://i228.photobucket.com/albums/e...327_164509.jpg
http://i228.photobucket.com/albums/e...327_173314.jpg

- - - Updated - - -

Finishing up the short block assembly this weekend. Here I am getting all of the connecting rod clearances sorted out for the bearing sizes to be used on each one.

http://i228.photobucket.com/albums/e...402_140729.jpg
http://i228.photobucket.com/albums/e...402_144354.jpg
http://i228.photobucket.com/albums/e...402_144420.jpg

Getting the top end put together now
http://i228.photobucket.com/albums/e...402_155859.jpg
http://i228.photobucket.com/albums/e...402_163632.jpg

Thinking about some different plug wires now since this set needs to be replaced
http://i228.photobucket.com/albums/e...402_165204.jpg

- - - Updated - - -

A little tease of the new wheels I picked up a few weeks ago for a great deal. Getting them refinished and hopefully on the car in the next couple weeks.
http://i228.photobucket.com/albums/e...75191024_n.jpg

Way to bounce back. At least you have peace of mind knowing the ins and outs of the motor now. Looking fwd to the new wheels.

Nice update, that last engine shot should be framed and turned into a motivational picture. Are those oem 74 wires? IIRC the Accel wires I used to run on my 72 fit the 75 as well, and they are nice quality.

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Originally Posted by gtx

Nice update, that last engine shot should be framed and turned into a motivational picture. Are those oem 74 wires? IIRC the Accel wires I used to run on my 72 fit the 75 as well, and they are nice quality.

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I need to upgrade the wires mainly, this was just the old set from the 72. Hopefully I will have the new set installed in a coupe weeks since I have the engine just about ready to go, should be able to fire up this week I think.
http://i228.photobucket.com/albums/e...73686596_n.jpg

I picked up the newest addition to the intake system this weekend and will begin testing and flow documentation in the coming weeks. More information can be read here
http://www.blackheartmotors.net/blog...hm-maf-adapter

http://i228.photobucket.com/albums/e...48042441_n.jpg

http://i228.photobucket.com/albums/e...54851720_n.jpg

http://i228.photobucket.com/albums/e...62188857_n.jpg

I am working on getting the OEM exhaust fitted with the motor on the stand since it just makes things a little easier. The MAF adapter is also installed just for the photo...massive inlet ^_^

http://i228.photobucket.com/albums/e...99480701_n.jpg

Spent the weekend working on the car and getting a few things cleaned up some more. The last time I installed the engine and transmission I didn't bother cleaning the transmission up.
http://i228.photobucket.com/albums/e...30911805_n.jpg

It bugged me how nasty it looked so I spent a good bit of the day Saturday cleaning the case up a with a wire wheel. Nothing perfect but its a nice improvement from what it was, and looks a lot better.
http://i228.photobucket.com/albums/e...25531899_n.jpg

I debated about modifying the wiring harness and getting everything tucked away neatly, but decided it was much work for now. To make it easy I am going to pick up another complete harness to redo so I can swap them out.
http://i228.photobucket.com/albums/e...66537667_n.jpg

Everything is ready to fire up again, just need a new water pipe O-ring ( :rant: ), then I can get the water crossover pipe back on and fill the cooling system. Should have a start up video later this week.

That maf adapter is so nice compared to mine. I won't mention names, but for $10 I guess I cant complain too much. The bolt holes didn't line up the greatest, casting marks on the inside, and the sides are slightly sharp and less blended.

I don't mean to make it seem the maf adapter overshadows the progress being made. I just find it impressive when parts designed to have the most efficiency no matter how simple they are.

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Originally Posted by 8thLS6

That maf adapter is so nice compared to mine. I won't mention names, but for $10 I guess I cant complain too much. The bolt holes didn't line up the greatest, casting marks on the inside, and the sides are slightly sharp and less blended.

I don't mean to make it seem the maf adapter overshadows the progress being made. I just find it impressive when parts designed to have the most efficiency no matter how simple they are.

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The MAF adapters that most people are using work well for that quick installation of any aftermarket intake system (or just a filter even), plus like you said they are very cheap to buy. There is nothing wrong with them, but by design they simply cannot offer what the BHM MAF Adapter will for the airflow capability.

The car now runs and moves under its own power as of last night. I have some things to finish up still with exhaust and wiring before its back to 100% but I am getting there.

:thumb_rsvd:

https://www.youtube.com/watch?v=w5LYXlpkyzY

Way to go on getting everything finished. Do you need a filter for your adapter? I have a 4.5" dc sports dry filter I think you might like. Its has a metal top and bases coated in wrinkle black that would go good with your manifold. Also has a funnel top and velocity stack base. I got mine on ebay, price wasn't bad either.

Sounds mean on my injen so I can only imagine on your car. Also can't really tell but are you using any piping for intake? If so seems short and direct.

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Originally Posted by 8thLS6

Way to go on getting everything finished. Do you need a filter for your adapter? I have a 4.5" dc sports dry filter I think you might like. Its has a metal top and bases coated in wrinkle black that would go good with your manifold. Also has a funnel top and velocity stack base. I got mine on ebay, price wasn't bad either.

Sounds mean on my injen so I can only imagine on your car. Also can't really tell but are you using any piping for intake? If so seems short and direct.

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Thanks!

I have a filter for the adapter, just running open element for a bit as the intake setup is not finished quite yet (that is another nice piece coming soon).

Nice, can't wait to see how you finish it.

Here are some more screenshots of a couple logs from going around the block. These are with MIVEC activated via a momentary button simply for investigating the knock.

As you can see from the logs there is minimal knock so far, with/without MIVEC operation. I can't say exactly where MIVEC is being triggers as this was just a temporary setup with the button to see how things are responding. Fueling still needs adjustment at this point, but the data speaks for itself in regards to the knock.

3/4 Throttle up to just under 6000RPM-
http://i228.photobucket.com/albums/e...67262401_n.jpg

3/4 Throttle roughly 4500RPM and above 110% load-
http://i228.photobucket.com/albums/e...20784694_n.jpg

This is an overview of the entire log from start to finish (from leaving the parking lot around the block and back). Minimal knock counts through the log-
http://i228.photobucket.com/albums/e...20883766_n.jpg

Looking good so far.

When swapping the motor out can the distributor and spark plug wires be transferred over to the 75?

After your adaptor I mean.


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Nothing new really to update, just been driving the car quite a bit lately. So far I have racked up about 2000 miles on the fresh rebuild and pulling about 26-27mpg which wasn't too bad. It is definitely doing really well in the mountains for the increased power.

This past weekend I took the car up Mt. Evans here in Colorado (Highest paved road in North America at 14,200ft), that was an interesting drive.
http://i228.photobucket.com/albums/e...84253551_n.jpg

Who needs guardrails ?
http://i228.photobucket.com/albums/e...20592905_n.jpg