My Hybrid Conversion

[1985ShlbyChrger]

I am doing a 2.5/DOHC hybrid swap. I am using a 99 2.4 DOHC head, an OBX SRT-4 tubular header ground to clear the oil drains, a rebuilt .040 over 2.5 with cast pistons(don't even hassle me :p) and otherwise stock bottom end(except ARP rod bolts) I already have the plugs in the head and have it resurfaced, but haven't gotten the block done yet. I don't have a puller for the crank sprocket so I can't get the crank out. I already have one of the oil drain backs figured out,which is the last pic. It snakes through the opening in the PS bracket(if I decide to keep the PS). I still have to figure the other one out. They will be wrapped with heat shielding, and the header will be heat coated as well. I will be running the distributor, and the stock Stratus intake clears it. I need to order the cam gears from FWD-P.

Here are pics of my conversion so far:

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/0112081517.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/0112081518.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/0112081451.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/0112081451a.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/0112081450.jpg

[1985ShlbyChrger]

No one even wants to look at this and/or comment? I feel so alone.

[mcsvt]

I was going to tell you it sucks, but figured I'd refrain.

But since you asked :D

[turbovanman²]

Looks good, your going to like 16 valve power.

BTW, get a better camera, ;) :thumb:

[Subliminal]

That would probably fit real nice in the front of a golden 600 'vert, me thinks. ;)

[1985ShlbyChrger]

That's actually from my LG VX9400 cell phone, I don't think they are too bad.

[TurboVanDan]

Can any of you fine folks tell me if there is a complete, step by step, well written out, in detail (with proper pictures), "how to" on prepping the 2.5 block and the turbo 2.4 head for hybridization anywhere on the internet? I mean, I have picked up on the major points by looking at a lot of different forum posts, but all the details just don't seem to be located in any one place. It would be awesome if they were...

And, by the way, don't let my usename fool you. My username is based on what I see in the future. Right now my van is only as close to being "turbo" as a set of SRT-4 wheels can get it... My van is a 1992 Caravan C/V with 2.5common block TBI with automatic transmission. I wish that is was already a 5-speed, but I will have to create that when I build my hybrid engine. Anyone know of an A568, shifter, and pedal set available for sale that will bolt right in to my '92?

[WVRampage]

I think you will have fun with this as Im working on doing one aswell only with the SOHC head.

[turbovanman²]

Can any of you fine folks tell me if there is a complete, step by step, well written out, in detail (with proper pictures), "how to" on prepping the 2.5 block and the turbo 2.4 head for hybridization anywhere on the internet? I mean, I have picked up on the major points by looking at a lot of different forum posts, but all the details just don't seem to be located in any one place. It would be awesome if they were...

And, by the way, don't let my usename fool you. My username is based on what I see in the future. Right now my van is only as close to being "turbo" as a set of SRT-4 wheels can get it... My van is a 1992 Caravan C/V with 2.5common block TBI with automatic transmission. I wish that is was already a 5-speed, but I will have to create that when I build my hybrid engine. Anyone know of an A568, shifter, and pedal set available for sale that will bolt right in to my '92?

There were some sticky's on this but there gone?

As for the pedals, trans etc, any 1st or 2nd gen van will work and fit. You can use car pedals if necessary, check out this link. I know a 5 speed van with all that stuff and I'll see if he wants to sell that stuff.

http://www.thedodgegarage.com/ddg_van_tech.html

[TurboVanDan]

Thanks for the info about the pedals, and I will check out out the link you sent (haven't gone there yet...). I was secretly suspecting that 1st gen van pedals would work in my '92 (or even car pedals as you suggest, turbovanman). And, in case you are wondering, I totally plan to use a "stand alone" for fuel and spark on my hybrid. Most likely MegaSquirt. My son has already built one MegaSquirt for his SRT-4 turbo modded '02 Dodge Neon ES 5-speed. It works beautifully...!! By using the stand alone, I will have continuous tuning capability, and won't need a distributor...!! Thanks again for the help. :clap:

I am still curious if anyone can point me in the direction of a concise, complete, detailed, with pics, place on the internet that teaches the 2.2/2.5 bottom with 2.0/2.4 head hybridization process....

Or maybe I just need to create this complete "how to" myself as I build my hybrid.... Got to get some parts rounded up first......

[TurboVanDan]

Oh, I forgot to ask... turbovanman mentioned that he knows about a 5-speed van that might have parts for sale. Approximately where is that van located? I am in northwest Missouri, but I would be willing to travel to remove parts. I would want to be careful to get all the clips, brackets, etc. that are needed. :thumb: And what year is the van...??

[turbovanman²]

Oh, I forgot to ask... turbovanman mentioned that he knows about a 5-speed van that might have parts for sale. Approximately where is that van located? I am in northwest Missouri, but I would be willing to travel to remove parts. I would want to be careful to get all the clips, brackets, etc. that are needed. :thumb:

Its the old John Deer van, its folklore around my neck of woods. I have semi sold it to a friend but he hasn't finished buying it and its in pieces so depending on what he is doing with it, all the stuff could be shipped out.

[TurboVanDan]

Ahh, so the van must be in British Columbia. What year is it?

[turbovanman²]

Ahh, so the van must be in British Columbia. What year is it?

Its a 1990, with a 568, :D

[TurboVanDan]

Whoa...!! An A568...!! Was it a turbo van? Also, I am curious if you can confirm that the shifter bracket that welds to the floor between the front seats is the same from 1st gen to 2nd gen minivans. Probably is, but just thought that I would ask.

I am keenly interested in these 5-speed van parts (even if they are in BC), primarily because of the one-stop shopping that includes an A568!! I wonder if the clutch is good too...?? And flywheel...??

Thanks for everything. :thumb:

[turbovanman²]

Whoa...!! An A568...!! Was it a turbo van? Also, I am curious if you can confirm that the shifter bracket that welds to the floor between the front seats is the same from 1st gen to 2nd gen minivans. Probably is, but just thought that I would ask.

I am keenly interested in these 5-speed van parts (even if they are in BC), primarily because of the one-stop shopping that includes an A568!! I wonder if the clutch is good too...?? And flywheel...??

Thanks for everything. :thumb:

Yes, its a 5 speed turbo Minivan, :thumb:

Clutch I would buy another one anyway as if your building a hybrid, you'll kill it and I am sure the flywheel is good.

[1985ShlbyChrger]

Well I've been making progress on my build. All the oil drains are done, two from the head and one for turbo. The oil feed lines are run, and the PCV equalization tube is in the process of being made. Should I use -6 or -8 for the equalization line? I drilled into one of the stock oil drains on the front of the 2.5 block and I'm going to drill into the 2.4 head to equalize the pressure but don't know whether to use -6 or -8 line. I'll get pictures up as soon as I find a camera. I aslo made my own spark plug wires and modded my distributor cap to use standard plug wires instead of the spade type. I also ditched the power steering. Who needs it?:confused2:

[Devsdaytona]

Are the exhaust ports and manifold bolt holes the same?

I heard they where different on 2000ish and up, including the srt-4.

[cordes]

Although blurry that looks really nice so far. I am thinking that I will do a hybrid for the next motor in my 600. Hopefully that will be a ways off as I haven't even gotten it on the road after a TII conversion.

Make sure to update the thread as you get more accomplished.

[Austrian Dodge]

Are the exhaust ports and manifold bolt holes the same?

I heard they where different on 2000ish and up, including the srt-4.

thats what i wanted to ask too...
can you post details on your oil drains, as i have the same head in my garage and want to put the same header on it ;)

thanks!

[shelbyplaya]

the 99- heads and th 2000+ heads are difernt and the exhaust will not fit.

[Devsdaytona]

how come he has a srt header which is post 2000 header and a 99 head.

hows that work, I need details:nod:

[contraption22]

the 99- heads and th 2000+ heads are difernt and the exhaust will not fit.

It can and has been done.

[Russ Jerome]

Can any of you fine folks tell me if there is a complete, step by step, well written out, in detail (with proper pictures), "how to" on prepping the 2.5 block and the turbo 2.4 head for hybridization anywhere on the internet?


Drill/tap these holes* as pictured,dont force in the plugs we just
want to fill the holes not crack the block:
http://hometown.aol.com/russjerome/images/judsblock.jpg.jpg
Then grind off as much as you can without touching the deck
of the block, let the machinest deck it. When done with that
we'll look at the head. Block should look like this when done:
http://hometown.aol.com/russjerome/images/dcp_0006.jpg

*Looks like 7/16" coarse and 3/8" on the bolts, other iron plugs
look to be 3/8" NPT...I forget but it doesnt matter you need a
decent complete tap set for the whole project.

[1985ShlbyChrger]

The bolt patterns are the same for the 99down and 2000up exhaust manifolds.The port shapes are different but they almost match up so with a little grinding they will match. There are two extra bolt holes that dont get used if you swap manifolds between the generations.I used a srt-4 header and I had to grind off the 'ears" where the extra holes would be so I could clear my oil drains.You can see it in this picture:http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00037.jpg

That is my right side oil drain for my head. I will be heat coating and wrapping the header, and I am getting the heat sleeves for the hose. Should keep them well protected. My left drain is the same way and will have the same heat treatment. Didnt get a good picture of that.

This is my crankcase equalization hose.Kinda ghetto but should work fine.http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00043.jpg

Here's it with the intake on
http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00045.jpg

Here's the turbo setup for right now
http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00042.jpg

And finally my fuel rail.It's a stock 1 piece fuel rail that I ground the mounting nubs off, cut a piece of tube to fit and welded it on. Should work perfect other than the fuel lines may be in the way of the thermostat housing.Easy fix for that problem.
http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00046.jpg

[moparfreak3]

You have anymore pics of the turbo and manifold? That is the same manifold I am using just with a Holset HX35 instead. Looks good I am pretty much doing the exact same thing just using a 04 head.

[cordes]

Looking good. Thanks for the update.

[JuXsA]

http://www.juxsa.com/carstuff/16v/16v.htm

Its not step by step but its got some good info

[moparfreak3]

Yeah I've been on your site a lot for pictures. I have to find someone that has pictures of the oil drains on the newer head because I have the 2 extra exhaust manifold bosses in the exact spot everyone puts their oil drains at. Do you think that I could put one in the side of the head and one between the 1 and 2 exhaust ports? Sorry to thread jack

[minigts]

Dude if I make it to Carlisle I'm going to bring my camera for you. :D Looks cool though.

I wish I had the money to do a 16v conversion...and time....and knowledge....and fabrication skills with a 'z' no less. I have mad nunchuck skills and I'm good with a bow staff, but that's about it. ;)

[cordes]

I have mad nunchuck skills and I'm good with a bow staff, but that's about it. ;)

Have you ever taken your car off any sweet jumps though?

[mboyek]

I don't have a newer style head, and I did not take a picture of my oil drains after they were completed and before the engine install. Sorry. But I did snake the passenger return through the power steering bracket. The power steering would have fit, however I wasn't thinking about my turbo and the exhaust, so the PS pump and bracket left. If I had different exhaust routing, it would work.

http://memimage.cardomain.com/member_images/1/web/2065000-2065999/2065059_30_full.jpg"]http://memimage.cardomain.com/member_images/1/web/2065000-2065999/2065059_30_full.jpg

Just the mock up

The sheilded line in the center of the photo is actually just a vacuum line, but if you look closely just below the ground strap is the return line that snakes behind where the power steering pump should be. Its shiny because its covered in heat shield.



http://i441.photobucket.com/albums/qq135/daytonaer/GEDC0050.jpg

Is your crankcase equalization tube NPT to hose fittings jb-welded in? Any specific reason for that? I used NPT to brake line flare to steel line, and feel like the flare seat reduces the I.D. of the pressure equilzation passages and creates a great spot for carbon build up and or gumming up the passage. I like the easily removable rubber hose, was the jbweld just to make it air tight?

[turbovanman²]

Dude if I make it to Carlisle I'm going to bring my camera for you. :D Looks cool though.

I wish I had the money to do a 16v conversion...and time....and knowledge....and fabrication skills with a 'z' no less. I have mad nunchuck skills and I'm good with a bow staff, but that's about it. ;)

Go TIII, hehehe, :evil:

[1985ShlbyChrger]

I just JB welded them to be sure that they won't leak, don't want to have to deal with leaks. And if the hose/valve cover crankcase evac doesnt have enough volume I can just run it off the NPT fitting in the front of the block and cap off the fitting in the head. Gotta get a few more parts and then I can finish this thing up.

I'll see if I can dig up some pics of the header and my big turbo.These pics are very blurry and I took them with my old phone, so no hatin on the blurriness.My new phone is much better and takes better pics so when I get the turbo back I will take some better ones. I'm not quite sure if the turbo is gonna clear the firewall or not, so I might have to BFH the firewall to convince it to move, or with my other plan it's gonna have plenty of room to hang out in the left side of the engine bay :D

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/0310081703.jpg
http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/0310081713.jpg
http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/0310082112.jpg

[turbovanman²]

Looks good except the only thing I would criticize is your oil drains into the block, you have them angled down.

[1985ShlbyChrger]

What's wrong with them being angled?I did that to make sure they will clear the axle and I also wanted to put them as high up in the oil pan as possible so that oil in the pan wont get sloshed up into them. I am making a windage tray and baffle setup also.

[moparfreak3]

Which holset are you using? I have an HX35 for mine.

[1985ShlbyChrger]

I am gonna try an H1E non gated, but I think the turbine housing is going to be WAY too big, so I may sell it andd get an HX35.

[moparfreak3]

Yeah I have the same feeling with my non gated hx. Mine has the 12cm housing on it. I will be really interested to see what kind of lag that it has once I get it running.

[1985ShlbyChrger]

Mine has the 21cm housing on it, It's HUGE. I may block one side off and see how that works but I don't think its gonna work too well. Thats why I'll probably sell it and get an HX or just find another housing to put on it.

[Boostin]

Hey whats up man! Nice job so far on the hybrid. Im in the process of doing the same and im also using the OBX manifold on a 99 head as well. Its nice to see it all working out for you!

[whywoody]

I use a HY35 with my hybrid,which is a 9cm turbine housing.
Stock,the internal wastegate couldn't come close to controlling boost...so I modified the housing by increasing the radius into the wastegate port and enlarging the port's diameter as much as possible.It's great now,no creep at all.
I had a 12cm HX35 to choose from at the time of building also,and noticed that the internal 'gate was noticeably smaller in diameter than the HY35 of the same year (99)...so I don't know if it would be able to keep up in stock form,even though the housing is larger and would flow better.
With a modified adjustable T2 large can style actuator set 'tight',and boost set at 20psi via a grainger,boost response is fantastic.I find boost comes on very strong from about 2500rpm and builds insanely quick from 3000rpm onwards.This is with a log style exhaust manifold,3" intercooler plumbing,big IC,stock stratus TB and intake manifold,and currently using the 2ltr cams too.I used the 2.4ltr cams for a long time,and may switch back,as they seem to produce gobs of mid range torque giving great fuel economy (wheel spin is a big problem around town with these though!)
Hope this ramble helps a little.

[1985ShlbyChrger]

Well I ordered my head studs finally. Its coming together. Bottom end is all together and ready for the head to go on as soon as the head studs get here. Hopefully it gets done in a month or so.

[1985ShlbyChrger]

New pics. Engine is put together. Just need to fab an intake and figure out my cam gears, whether I'm going to buy them or fab them, and some other miscellaneous stuff. Should be together and in the car soon.

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00001.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00006.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00007.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00008.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00009.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00010.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00013.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00014.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00021.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00022.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00023.jpg

[jl93sundance]

What happened to that big A$$ turbo that was on there before:evil:? Otherwise looking good.

[moparfreak3]

Looks great yours is a lot farther along than mine. My block is still sitting at the shop. But yeah did you ditch the holset idea in favor of a smaller turbo?

[1985ShlbyChrger]

The holset I had was WAY too big. I am using a stock T2 turbo with a .63 phurd housing for now until I find a non wastegated H1C.

[Darkapollo]

Wow. how did i miss this thread for this long? nate let me know when u want me to swing by and help! u know im busy these next two weekends but after that im free.

[dds78910]

So is the tee on the back of the head the oil supply line for the head and the turbo?

[Aries_Turbo]

nice job nate. :)

i have one of these heads sitting at my house as well. :)

brian

[t3rse]

looks good...keep in mind that oil will eventually eat jb weld, if that is what you used to seal the oil returns as it looks in one of the pics

[1985ShlbyChrger]

Yes, the tee is the oil feed for the head and turbo. I figure it's easier to do that with stuff I had laying around than to have new lines made.

Dana, you're blind. That's how you missed it. All I need is my cam gears back from the machine shop, buy a timing belt, get the 4" tubing and have it welded for the intake and it's in the car time. Ill def need help with that.

Brian, me thinks that a hybrid would look just as good in your 2 door as it will in my 4 door. Sounds like it's time for a hybrid conversion.

And yes, I know the JB weld won't hold forever. It was just to make sure they won't leak. The fittings in the head are very tight so no worries there, but the drains into the pan will need to be done with some better pipe and welds.

[Aries_Turbo]

yeah I know its time. :)

ive been gathering parts for a little while. :) i am getting one of those neon coil adapters from 90TurboVan on TD, i have the head and 2.0L cams and a stratus intake. all ill be using the distributor for is for the synch signals so i dont have to have the cap on there. it will be pretty low profile. i just need cindys cam gears and to start fabbing things up. i have a borg warner s200 turbo as well. hope its not too big on the exhaust side as i havent measured it yet.

Brian

[whywoody]

What exactly happens to the JB weld when exposed to oil?
I've had mine running for along time now and haven't had leaks with any of the JB I used,and it's everywhere lol!

[1985ShlbyChrger]

Well I ordered my megasquirt today. Easier to do that than to burn chips and keep swapping them out. Got it for a good price so I snagged it. Cam gears should be done next week and then its gettin close to bein done. I can't wait.

[1985ShlbyChrger]

Engine is almost complete. Just a few things to do and in the car it goes. Here are some recent pics. And yes, they are kinda blurry, I know.I also bought a bigger turbo. Not sure exactly what I bought but its pretty big. Got a good deal on it and the Turbonetics Evolution wastegate so I bought them.

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00088.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00090.jpg

http://img.photobucket.com/albums/v237/88shadow/16v%20Conversion/IMG00091.jpg

[t3rse]

What exactly happens to the JB weld when exposed to oil?
I've had mine running for along time now and haven't had leaks with any of the JB I used,and it's everywhere lol!

It eventually becomes brittle and falls apart. That said, I filled the O-ring grooves in my block with JB weld because it became impossible to find the proper gauge copper wire and ran the car like that for two years with no problems.

[jl93sundance]

looking good, are you going to be fabbing up a custom intake or just using the stratus one? Also what timing belt tensioner are you running?

[1985ShlbyChrger]

I'm using the stratus intake for the time being. My custom intake is being made. I'm running a tall deck timing belt tensioner flipped around and mounted in the bottom hole for the power steering bracket. Works perfect. Engine is in the car now and almost everything is hooked up. Tackling the MegaSquirt wiring is next on the chopping block.

[86turboz]

This may be a stupid question, but is there a method to choosing where your oil feed, oil drain, and pressure equilization lines go, or is it just anywhere that makes it easy to route the lines?

This is probably a stupid question, so feel free to give me the idiot proof answer:o

[1985ShlbyChrger]

Oil feed is wherever you think its easiest for you. Oil drains have to be at the lowest point in the head or the oil will puddle before it drains. Pressure equalization line is high up in the block so it doesnt suck oil up. And yes, it's pretty much wherever it's easiest to route them.

[8shelbyz8]

What belt are you using? I'm trying to run the hybrid belt from FWD but having problems with it running through where the motor mount bolts to the block.

[1985ShlbyChrger]

The same belt that you have. I'm having no issues with belt fitment. What hole do you have your tensioner in?

[8shelbyz8]

alright that's good. I didn't realize putting it in the lower hole would solve it. I ordered a 2.5 tensioner last night and it should be I'm tomorrow. Thanks for the help.

[1985ShlbyChrger]

Got to working on it a little more, and its coming together. Had to make a clearance dent in the firewall for the turbo, no big deal, it's just a k-car beat away. Still havent done the wiring, no interest in that haha.need to extend some wires for the TPS and AIS, order some piping for the exhaust and intercooler and install the intercooler. Pics will be in order shortly.

[86turboz]

Got to working on it a little more, and its coming together. Had to make a clearance dent in the firewall for the turbo, no big deal, it's just a k-car beat away. Still havent done the wiring, no interest in that haha.need to extend some wires for the TPS and AIS, order some piping for the exhaust and intercooler and install the intercooler. Pics will be in order shortly.

just curious, how do you plan on running your coolant system? are you gonna block off the block tstat housing and use the intake one or vice versa?

[1985ShlbyChrger]

As of right now, with my current intake the tstat housing is still on the intake. I'm going to use that until I figure out another intake.

[86turboz]

so are you just blocking off the one on the block?

[1985ShlbyChrger]

Blocking what off on the block? There is no tstat housing on the block.

[86turboz]

Blocking what off on the block? There is no tstat housing on the block.

Forgive my stupid question....I dont know what I was smoking....lol. Thank you

[myplasticegg]

is this thing running yet?? I'm going to start one soon... gonna be crazy stuff man, crazy. Give me a call, same number.

[jl93sundance]

is this thing running yet?? I'm going to start one soon... gonna be crazy stuff man, crazy. Give me a call, same number.

I think he sold it all to another member.:thumb: