89 Caravan ES 2.4 Turbo Swap

[turbo84voyager]

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.

[turbovanman²]

Another 2.4 van?

That should be awesome, sounds like a lot of fun. 46 trim? A bit small don't you think? ?

[RoadWarrior222]

Sounds good to me, probably run a 12.56 first time out...

I don't see any injectors, I'd recommend you get some, the engine starts much easier

[turbo84voyager]

Another 2.4 van?

That should be awesome, sounds like a lot of fun. 46 trim? A bit small don't you think? ?

I considered putting it in my shadow convertible but the car is all done and I really dont want to pull it apart again. Then I thought about the 84 van, but that is my "baby" that I take to car shows / cruises and the 2.5 turbo w 5-spd in it runs great so I am not going to tear it apart.

As for the turbo, I am running this turbo on the current engine. It is larger than the stock mitsubishi on the 2.4 and since the van is a daily driver I think it will work pretty well with this combo. I am open to any suggestions. I posted a message a while back about using this turbo and several felt it would be very streetable and that is what I am looking for. My 84 voyager is much more fun around down with the T3 turbo than my 89 is with the T3/T4 so I am thinking with the much better flowing head on the 2.4. The turbo should work well.

Sounds good to me, probably run a 12.56 first time out...

I don't see any injectors, I'd recommend you get some, the engine starts much easier

I am going to start with the 40+ injectors from the 8 valve engine and go from there.

[RoadWarrior222]

Tru dat, you really have to ram the air into the 8v, but the 2.4 should lap it up.

[1BADVAN]

I recently painted it Acura nighthawk black with Jeep gray bottom, painted grille and installed 18” 5-spoke wheels.

Pics? I would love to see the pics of the paint and rims!

[turbovanman²]

I considered putting it in my shadow convertible but the car is all done and I really dont want to pull it apart again. Then I thought about the 84 van, but that is my "baby" that I take to car shows / cruises and the 2.5 turbo w 5-spd in it runs great so I am not going to tear it apart.

As for the turbo, I am running this turbo on the current engine. It is larger than the stock mitsubishi on the 2.4 and since the van is a daily driver I think it will work pretty well with this combo. I am open to any suggestions. I posted a message a while back about using this turbo and several felt it would be very streetable and that is what I am looking for. My 84 voyager is much more fun around down with the T3 turbo than my 89 is with the T3/T4 so I am thinking with the much better flowing head on the 2.4. The turbo should work well.



I am going to start with the 40+ injectors from the 8 valve engine and go from there.

Just buggin, the 46 trim will be fine. That's my only issue with the GT turbo is lag and around town driving, but if I want to run the times I want, I need it.

+40's will work just fine.

Pics?

[INVUJerry]

This is what I'd like to do to my 93 voyager eventually, I'll be following this build. The 2.4 is a great motor that can make good power. A cheap upgrade for cams is to use a 2.0 dohc neon intake cam.

[turbo84voyager]

Here is a few pictures of the van and some of the engine parts. I have the crank, cams and a few other parts in a closet and I didnt want to drag them out for pictures so they will be in future pictures.

Below are shots of the head all wrapped up from the machine shop. On the bottom you can see the new OS Stainless valves.


Here is a shot of the boxes of new parts ( bedplate sealant, lifters, bearings, balancer) on the right is the Darrel Cox treated oil pump.


The block, ready for assembly. I have a RWD bellhousing and ND starter for clearance if I ever decide to use a TD trans some time in the future.

CP 8.5:1 pistons

Eagle Rods

[1BADVAN]

Looks good!

[BIG PSI]

Tell me about those rims on the Van ?
What size are they----------------------16-17-18" by what width.
What size are the tires ?

Looks really nice.
Chuck

[turbo84voyager]

I am not sure of the width of the wheels, I bought them off a family member with the tires already mounted. They are 18" with 235-45-18 tires. The wheels were off of a mazda RX8. The tire size is 1 size too wide and or the offset is off a little. I installed Tauras studs ( longer than stock studs but fit the hub) and spacers. I cant remember the exact sixe of the spacers but they are not that thick ( either 1/4" or 5/16") and i got them at the local auto parts store (Dorman brand). This is definately the widest tire you can put on one of these vans without them sticking out. When I wear these tires out I will probabily go with a 225-45-18 tire.

[contraption22]

Awesome! Good luck!

[turbospirites]

I love the look of your van! keep us updated.

[turbovanman²]

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