Since I have never documented any of my previous projects on the forum I figured with all the other 2.4 stuff going on I would start a log of this project. This project started 2 years ago and should have been completed but was postponed due to my son being born and an issue with my hand which I have had surgery. Two years ago I picked up a 04 PT GT 2.4 turbo engine with approx 50k. I was told the engine had a knock but was complete including the turbo and an 06 plastic intake for $250. I pulled it apart and it definitely had a knock. I took rod 1 bolts out by hand and 1,2 and 3 rod bearings were spun. I never pulled the oil pump apart but my guess is the gear broke. The van is an 89 Caravan ES and currently has a built 2.5 (Wiseco’s, ported head, turbonetics T3/T4 turbo, header, Volvo intercooler, custom 3 bar 40+ cal. Aeromotive 340 fuel pump etc.) I recently painted it Acura nighthawk black with Jeep gray bottom, painted grille and installed 18” 5-spoke wheels. Inside the van has autometer boost, EGT and Dawes A/F in a pillar pod and an AEM wideband on the steering column.
Below is a list of what I have for the build:
04 2.4 Turbo block and head
balance shafts removed
900 mile "take off" cams and followers
CP Forged 8.5:1 pistons
Eagle H-beam rods
New Mopar crank
Clevite bearings
Mopar Performance Lifters (same as stock SRT but cheaper to buy)
New piston oil squirters
Darrel Cox Racing mod / treated oil pump
1mm OS stainless valves ( back cut)
I was going to use megasquirt and built a JimStim but decided to use the SMEC for now
Rich Bryant Distributor Adapter
FWD Performance stage 5 2.4 calibration
New Mopar stratus balancer
Stratus accessory brackets
96 2.4 Caravan front mount
I have both a stratus and neon side mount bracket. Not sure what I am going to use.
46 Trim turbonetics turbo
Homemade header
Neon 413 transmission
Isuzu NPR intercooler
RFL BOV
I am going to run the 40+ injectors from the 8 valve engine. I will upgrade as needed
I recently replaced the 255 Walbro with a 340 Aeromotive fuel pump.
I am hoping to get the rotating assembly balanced by the end of the month and then I can assemble the engine. All of the machine work is done and the head is ready to install. I also clearanced the block in the back incase I ever decide to use a TD transmission with it. I will get some pictures posted soon.