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Jamie's 92 Hyundai Elantra with bastard 4g63 swap

There's a history both behind this car, and the friendship with this person. I met him 10 years ago following a random conversation that I injected myself into between 2 strangers at an auto parts store. I had just bought a '92 Civic CX with crap compression and was picking up some service parts to keep it limping and useful while I built my DSM. I overheard him mention "4g63" to somebody as I walked by, so I turned around and introduced myself without any clue that he was one of the "realest" people I've ever known. What occurred for me in the following discussion was an awakening on my part. He led me to an adjacent parking lot where an un-assuming Hyundai Elantra sat. This isn't the one, but is one of many factory cars that he's swapped a 4g63 into. What he managed to get through my big thick skull was there were lots of great inconspicuous chassis that you can simply bolt a 4g63 into. Over time it became evident where you can find lots of "racing" parts, from factory equipment on various mini-vans, station wagons, much of the Hyundai line-up from '92-'95. During the "DSM Years", there were plenty of cars from other manufacturers that made dynamite donors, and this sparked my ability to be frugal in some of my ventures. If you ever meet Jamie, expect his knowledge of car parts both inside and outside the realm of Mitsubishi to be as unassuming on the surface as the car in this video. He has true talent. Finds peace and happiness in a junkyard full of decay, and skills that create useful high-performance art from what many consider rubbish. Because he's already taken time walking around with parts from one car and bolting them on to others to see if they'll fit, worked as a machinist's apprentice rebuilding everything under the sun, and done the tech work to analyze failures in all of it, he's often my go-to guy for advice when things aren't working correctly. Many times he's come through for me in a pinch and shed light on something I didn't understand. That goes both for examples in the automotive domain, and in real life when I've hit hard times. Many of my parts for the Colt came from his past builds on various Mitsubishis and Hyundais. In fact... many of my Colt parts have come from this very car. He gave this chassis to somebody, and they returned it later because life didn't let them finish it. I don't think it took even a month once he put his mind to working on it to get it in this state, and it was motorless-and-in-pieces. I can't wait to see these parts get bolted on this car. I think we'll have a new textbook definition of sleeper when he's done.


 


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Hyundai Assembly 5 - Fighting The Valve Clearance
In previous videos I showed the 2 factors that really need to be scrutinized. Valve clearance and how you degree your camshafts. Of course we got sidetracked with plenty of other tips and tricks but I wanted to upload this video to illustrate that the process really isn't as easy as the animations, demonstrations and explanations make it look. The reasoning is sound, but the work to execute it can be very tedious. Setting up the valvetrain on this engine was very tedious. I say "was" because following this video, we can put that whole topic to bed. This is what it took. Not many people have the patience to deal with this, and I wanted to showcase here for those who are at the peak of their frustration with their builds. This kind of stuff can happen to anyone. Let my pain and suffering help you not feel so all alone. My apologies for the lack of new groundbreaking technical info. It's not a complicated task to install ARP head studs, and that was my plot twist. There are a couple of hurdles you may encounter depending on the production year of your engine, but they're well illustrated in this video. I'm not sure if their installation warrants a video all unto itself, but if you feel it does, speak up because I have 3 more engines to build. I can still do it. I just wanted to demonstrate that progress is being made on this, and despite the long breaks between uploads, a LOT is going on behind the scenes. This was 20 hours of repetitive work and I hope it's at least mildly entertaining. For me, this was the most boring video I've ever edited here because I had to re-live the same steps so many times, over and over again. I could very easily have inserted an hour of it in the wrong place and nobody would ever have known because it all looks the same. The text overlays are there only so you can be aware of what's different. A voiceover would have been pointless because the techniques illustrated are discussed ad-nauseum in the Cylinder Head 205 and 206 videos. The valve cover gasket installation process was covered in "Valve Cover Modification and Polishing", and the discussion about compression ratios is explained in "Calculate Your Compression Ratio". If you like the job the parts washer did, check out my DIY parts washer video. ;) Cylinder Head 205 https://www.youtube.com/watch?v=wbWWCKPuZG4 Cylinder Head 206 https://www.youtube.com/watch?v=4s2X3VUwADA Valve Cover Modification and Polishing https://www.youtube.com/watch?v=NiIi9EljLSk Calculate Your Compression Ratio https://www.youtube.com/watch?v=bWze92nt9OU





More ebay 20g drag passes
Trolled by mother nature. I thought plugging in my o2 sensor might make a difference. Scarily that's not how things worked out. My fuel trims are all jacked up with or without it. Airflow counts are down. I have more to do to this thing, but in an effort to keep things real, I'm uploading what happened and what I found in the logs. The PRIMARY reason for racing is development of both self and your equipment. If your goal is to have an awesome street car, you can't fully-achieve that goal without rigorous testing where numbers and facts are clearly evident. You JUST CAN'T do that on the STREET. There are no numbers on the street, no measurement of a baseline nor any improvements you might make. There's no measurement of a drivers' skill outside of, "did you win or didn't you?" I didn't come to the track with the expectation of MY driving needing to be improved. I was simply getting numbers, so I wasn't a tree-nazi like I was in the Friday Night No-Lift-To-Shift video. There was more incentive for me to just not red-light and see what she'll do. This evening I didn't feel like the track crew were on their A-game. Sometimes they held staged cars for an inordinately long period of time... which once I'm staged, I'm on the rev limiter, and once they left me there awaiting the tree for over 20 seconds, heating my car up and leaving me disadvantaged out of the hole. Other times they treated the starting lanes, dried off my opponent's side but not mine, not giving instruction to hold or wait. In fact, one guy was signaling me forward while another crew member was standing in front of my car spraying the lane. What do you expect for only $15? I'm grateful for them, but the communication could stand improvement over what I saw tonight. Perhaps I'm just a bit miffed with my setup and looking for someone else to blame? The track officials certainly don't deserve any for how it ran this night.





Wheels, Plastidip and Mickeys
What starts as an innocent venture into wheel painting ends in a sticky, sticky episode of badassery. Plastidip is spray-on rubber. This is the first time I've ever worked with it. My review: It comes in colors but my favorite is black. It's good stuff. What I did should have had me spraying it on last... because mounting tires will remove it from a wheel. Most people doing this painted their wheels while tires were mounted. This is what happens when you don't. So what? It's spray-on rubber. Spray on some more and you're good. If you want the BEST results with it (since it can be expensive in some regions), allow no less than 10 minutes between coats, and spray LIGHT COATS. That's capitalized because squeezing out a light coat of spray-on rubber is much easier said than done. It's like lightly-spraying Silly String, or setting your fire extinguisher to "low". Or trying to bathe in a waterfall with good intentions, but getting knocked on your ass by the force of falling water instead. I'm amazed at how easy a product like this is to work with in concept. It sprays differently than paint, but its application is easily mastered once you get the feel for it. I give it... d (ツ) b





Hyundai Elantra 4g63 Shortblock Assembly
HOLD ON TIGHT! HERE WE GO! We begin the blueprint and assembly on my 1992 Hyundai Elantra's bastardized 4g63. The parts used in this are from a mash of different brands and models outside of the typical 2.0L 4g63, but the specs and standards I am following for its assembly are for the 2.0L DOHC. If you want to follow along in your service manual to verify what I've done here in this video, the processes we cover here detail pages 11C-95 through 11C-105 of the 1g Overhaul manual. I would prefer you not rip them from the binding and throw them away, relying only on this video for instruction... but rather use this video as a motivational guide, and as a demonstration of the techniques involved in those sections. You gotta do the cooking by the book. I never had any intention of making instructional videos on this particular car, but after it blew up I slowly realized it's actually a better case study for how a 4g63 ticks than anything else in my driveway. There are several reasons for this. One being that it's a mix of parts that shouldn't be bolted together, and the other is that many of you watching my videos aren't trying to build a 600hp engine out of aftermarket parts. You're trying to put back together what used to be your daily driver. This car covers those bases. Don't think for a second I won't go through this same trouble and level of detail for the GSX. I will. When I do, having this information in this video will give you a better understanding on how and why I do things the way I do when I get there. This was the shortest I could condense this video. I've never uploaded a video this long, and I hope I never have to do it again. It took a month to create on cutting-edge equipment, 16 hours to export, and 9 hours for YouTube to process. My script for the voiceover is 6 times longer than the whole script for the movie Pootie Tang. 6 times. Longer. Than a Hollywood movie.





Jafro's Hyundai Elantra Surprise
There are some things you can't put a price on. I'm not just talking about the Hyundai. I'm talking about Jamie. I have the best friends in the world. Look what Jamie just did for all of your entertainment. He literally donated it to me to play with on this channel. This isn't just for me. Think about it. It's the only FWD DSM in my driveway, and the only one I'm likely to have. With this combination of parts, I could not have a greater challenge making this car stick. Because right now it doesn't at all. Torque steer ends at about 5700 RPMs in third gear. Boost is instantaneous. This car could never make good use of any larger of a turbo. I'm convinced with the right combo of tricks to gain timing and tweaks to make it stick, and that it will run deep into the 12's just like it is. This car is a kick in the pants to drive. A rolling burnout. Be careful with that downshift.





First ebay 20g drag passes
I made 2 passes. On the first one, nearly everything that could go wrong did. But I'm a persistent bastard. I fixed it all, found everybody and then made this run. It wasn't until after I got home that I realized I had no in-car video footage of the first run when I broke despite having set it up... I kicked the alternator belt off no-lift-to-shifting into 4th gear around 800 feet and coasted to a 13.3 at 82mph against a 10 second Mustang. Overheating with no power steering I limped it back and put the belt back on, only burning myself 9 times, and then got back out and made this run. The guys in front of us broke, too. I guess it was contagious?

This run is on 93 octane pump gas.

I shouldn't have been in such a hurry. It left me a little unprepared. You learn things about other things while doing things--is the best I can explain it. It didn't knock at all, so clearly the new injectors are working fine... but I didn't take time to burp the coolant system, so it ran hot. My alternator belt was loose, and it bailed on me. I was focusing on explaining the video (I deleted that scene from frustration) rather than putting the car back together, and failed to plug in a very important sensor. I would have caught it, but didn't get a chance to look at the logs until I got home. I have to operate so many pieces of equipment in addition to actually driving that it's very distracting.

The guy in my second race had a beautiful 1967 Dodge Dart, and he was a very good sport! It was a great race where adrenaline is involved, and I was focused but wary of whether or not the alternator belt would stay on. I really appreciate the guys that keep old muscle alive. That car's almost 50 years old. That's making history right there... He cut a great 60 foot after they cleaned up the track, but I wish that car didn't break in his lane prior to his pass if it was a problem for his run.

I tried to leave nothing out and keep it short & sweet. I was lucky to have a track-side cameraman for the second race. Thanks Taylor! Having that sensor plugged in would have left me much more confident in the log data and offer a much better assessment of this turbo, but it is what it is. Here it is...





Why so SIRIUS? Kia 4g64?
This video assumes you're aware that various iterations of the 4g series Mitsubishi engines are designated as Sirius I & II. For detailed information about which engines qualify as which, visit: http://en.wikipedia.org/wiki/Mitsubishi_Sirius_engine There's also this at EvolutionM: http://forums.evolutionm.net/evo-engine-turbo-drivetrain/278462-official-hyundai-2-4l-g4js -4g64-thread.html Good luck finding info about this using Hyundai and Kia in searches. Wikipedia doesn't have any info about it grouped with the Sonatas either. There is no question what this is, well illustrated in this video. I apologize for the length of this video, but a lot of ground is covered in a short time. Hopefully there's some information in here you may someday use. I'm just trying to expose it because there doesn't seem to be any real information floating around in the forums about this yet. The car is a first-generation 1999-2005 Kia Optima sedan. It has the EVO equivalent of a 4g64 2.4L. Before using any of these parts, do your research, cross-reference your parts and know what you're getting into. Using parts from this rotating assembly in a 2g Eclipse will require aftermarket rods and/or custom pistons. This is information for those who wish to frankenstein their builds, or save a buck... whichever.... either one of those requires skill.





lancer evo build 4g63





4g63 Block Oil Gallery Mod
This modification is intended to improve your 4g series engine's oil delivery. People frequently discover large chunks of flash in their engine's main oil gallery. It's because the galleries are part of the cast, they're not machined into the block. There is also a very rough sharp edge where the main oil gallery is bored into the block, and oil must make a slightly greater-than 90° turn in order to begin its course to the parts it lubricates. Both of these conditions cause turbulence in the oil flow. My goal in this video is to eliminate as much of that as I can. This is a cheap and easy modification if you have the tools, and the patience. Any engine with cast-in oil galleries could probably benefit from this. Be careful not to cut into the high pressure oil gallery or else you will circulate un-filtered oil to the #1 main, oil pump, and rear balance shaft. You will also deprive the rest of the engine the oil pressure it needs to operate. So in short, punch a hole in that and it's trash. I did this my way, everyone may choose to do this a different way. I just wanted to make this video to raise awareness. Also, there's a great thread on DSMtuners about this. Pictures and everything. Written by a machinist and friend of the DSM community. Go give him some reps because he's posted a lot of great info about the DSM oil system over the years. http://www.dsmtuners.com/forums/articles-engine-fuel/452546-4g63-block-oili ng-mod.html





Grinding Oil Return Channels
I started cleaning the rust out, and got carried away. I didn't want to do as extensive of a cleanup job as I did on the GSX, but still wanted to make improvements because of the kinds of oil-related problems it experienced. There's a method to this madness. It will make more sense once I get around to bolting the oil pan back on. The techniques in this video are things I had to do right now if I was going to do them at all. Some of them really needed to be done anyway. You really don't see people do these tricks on imports. Just because you don't see it, it doesn't mean it can't help. I hope you enjoyed the motor oil drag races in the middle of the video. They speak for the science behind this mod... without having to get all scientific. Those results speak clearly for themselves, and there's plenty of chances to get scientific as the Glyptal treatment of the GSX is completed. In this video... I used steel wire cup brushes for both an air DIY grinder, and a Dremel to remove the rust. I used a cone-shaped carbide double-cut burr to smooth the crankcase. I polished the crankcase with coarse and medium sanding rolls for both an air DIY grinder and a Dremel. I used a 1/4" ball carbide double-cut burr to grind the channel. I used a pack of Harbor Freight #95947 10-Piece Tube Brush Kit. http://www.harborfreight.com/10-piece-tube-brush-kit-95947.html





4G63t Swapped Hyundai Excel
4G63t Swapped Hyundai Excel.... Vtec this... 2100lb full interior... Engine Specs: Maybe Later....





Hyundai Assembly 6 - Manifolds & Turbo
I love music videos. They're so much easier to narrate. I don't want to upset anyone by not providing commentary about what I'm doing or where this build is going... and this is the video where all that stuff comes together. Quite frankly, I missed you. I really enjoy these little talks we share. In this video is a little fabrication, maintenance, comparison and assembly. Un-boxings, cleanup, break-fix... Variety! You know... The stuff that keeps happening as you wrap up any build. It's not a longblock until it has manifolds, and a turbo build has a few more things than just that in order to make it complete. My attention has now turned towards preparing the chassis and accessories for installation and I promise there will be more involved videos following this one for the hardcore auto techs. Whether you're watching or wrenching on this one, all this stage does is create anxiety for wanting to hurry up and finish the install, but don't rush. Do it right! These are the non-reusable parts for the turbo install. ALL of the other part numbers in the video were shown: MF241255 x2 Oil Drain Bolts (upper) MF101229 x2 Oil Drain Bolts (lower) MF660031 x2 Oil Drain Gasket (washer) MR258477 x2 Oil Drain Gasket (flange) MF660064 x2 Oil Feed Crush Washer (turbo) MF660063 x2 Oil Feed Crush Washer (head) MF660065 x4 Coolant Crush Washer (turbo) MD132656 x4 turbo Bolt (M10 x 80 x 1.25mm) MD132933 x8 turbo Spring Washers Thank you all for keeping up with this build. Thanks especially for the kind comments and interest in this project! You guys are the best!





Cylinder Head 206 - Valve Clearance (& LSA)
This video is the companion and continuation video for Cylinder Head 205. In Cylinder Head 205 we covered the tools and technique for setting valve timing versus the factory-recommended specifications. It didn't work, thus; this video. How do I know it didn't work? Watch this video. The reason this is a companion video is because anyone changing their valve timing must also CHECK their valve clearance or risk bending valves. If I can install aftermarket cams, then I have made significant changes to my valve clearance. If I move cam gears on an engine that was previously running, then I have made significant changes to my valve clearance. If I have milled my head or block, I have made significant changes to my valve clearance. If I have installed larger valves, I have made significant changes to my valve clearance. Mitsubishi doesn't build a whole lot of wiggle room into their valvetrains. They keep the valves pretty tight to maximize performance and a 4g63 IS an interference engine. Note that if you follow the recommendations in this video and damage your valvetrain that I am not responsible. Here I demonstrate all of the techniques to ensure that damage never occurs because these tests are performed PRIOR to the engine ever starting, and prove that clearance is adequate for THE PARTS I SHOW HERE ON CAMERA. There can be components installed in other rotating assemblies that require additional clearance to be built into your valve clearance such as aluminum rods, or other alloys employed in the casting and forging of rotating assembly parts and valves. I strongly urge you to check with those manufacturers for their recommendations regarding thermal expansion, stretch, bounce rocker gap or float prior to making any adjustments, and use this video only as a documentation of my experience. In other words, it's my opinion. What works in your engine will likely be very different from mine, but the tests and the math shown here will work the same with your build. To find your intake valve clearance... Add your intake valve opening degrees (btdc) to your intake valve closing degrees (abdc) to 180°. IO + IC + 180 = DURATION DURATION ÷ 2 = LOBE CENTERLINE LOBE CENTERLINE - IO = INSTALLED INTAKE CENTERLINE To find your Exhaust valve clearance... Add your Exhaust valve opening degrees (bbdc) to your intake valve closing degrees (atdc) to 180°. EO + EC + 180 = DURATION DURATION ÷ 2 = LOBE CENTERLINE LOBE CENTERLINE - EC = INSTALLED Exhaust CENTERLINE To get your Lobe Separation Angle, ADD your INSTALLED INTAKE CENTERLINE to your INSTALLED Exhaust CENTERLINE and divide that result by 2. Intake Centerline + Exhaust Centerline ÷ 2 = LSA Tight Lobe Separation Angles * MOVE TORQUE LOWER IN THE POWER BAND * INCREASE MAXIMUM TORQUE OUTPUT * INCREASE CYLINDER PRESSURE * INCREASE CRANKING COMPRESSION * INCREASE EFFECTIVE COMPRESSION * INCREASE COMBUSTION CHAMBER SCAVENGING EFFECT * SHORTEN YOUR POWER BAND * REDUCE IDLE VACUUM! * REDUCE IDLE STABILITY * INCREASE LIKELIHOOD OF KNOCK! * INCREASE OVERLAP * DECREASE PISTON TO VALVE CLEARANCE! Wide Lobe Separation Angles * MOVE TORQUE HIGHER IN THE POWER BAND * DECREASE MAXIMUM TORQUE OUTPUT * LENGTHEN YOUR POWER BAND * DECREASE CYLINDER PRESSURE * DECREASE LIKELIHOOD OF KNOCK * DECREASE CRANKING COMPRESSION * DECREASE EFFECTIVE COMPRESSION * INCREASE IDLE VACUUM * IMPROVE IDLE STABILITY * DECREASE OVERLAP * DECREASE COMBUSTION CHAMBER SCAVENGING EFFECT * INCREASE PISTON TO VALVE CLEARANCE There's more that I want to say about Lobe Separation Angle (LSA). If you're tuning a DOHC engine with cam gears, you're very lucky to go through all this trouble. The pushrod and SOHC crowd can't change their lobe separation angles without replacing their camshaft, and on many engines that means removing the cylinder heads. On a 4g63 with adjustable gears, you loosen the lock bolts, turn, lock it back down and you've adjusted your LSA. This is a luxury which if you've never had to build a SOHC or a pushrod engine and install camshafts that you take for granted. DOHC tuning permits the ability to alter the opening and closing events of the valves independently of one another and perfect the valve timing during tuning without having to completely remove and replace the valvetrain. What this also means is that the pushrod crowd needs to know and understand a lot more about their camshaft profiles prior to making their purchase as we [the DOHC crowd] do. They have to be on their A-game when they drop the coin on a new cam or else things get expensive really quick. Lobe separation angle says more about how camshafts behave than duration and lift, but all 3 should be carefully scrutinized when you're making that determination. Yes, I did actually animate my engine's valve timing exactly the way HKS said to set it up. Yes those are all actual photos of my parts. Yes that was the biggest Photoshop file I've ever created.





Install Clutch in a 1g Turbo DSM swapped Elantra
You guys asked for an update on a different project. I've been working on the GSX since November and this is one I could squeeze out without getting in the way of other projects. TRADE YA needs a clutch. It needs some other things, too, but I'm starting with the clutch. In this video I stay on point with the used-or-junkyard-parts build theme. This car doesn't deserve new parts and I've done all of this before, just never in one video. I need something to run at the track while I'm waiting for parts, polishing and machining. I'm closest to having that happening with the Elantra right now so let's get this over with. Consider this the cliff notes of the transmission series, and another step towards making a free car built from used parts run 12's.





6&7-Bolt 4g63 Front Case & Oil Pump Rebuild
Here we disassemble, clean, inspect and rebuild both popular 4g63 front cases. This is not difficult, you just need to know what to look for. Something else that happens in this video is the analysis of one of the factors that caused my 7-bolt engine to fail. It wasn't the only cause, and we'll talk about that later, but left to its own devices and without the other contributing factors, it would have been the only cause.





Which car is faster? Which Car is Faster?




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1992 Hyundai Elantra : 12.960 @ 108.420
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2002 Hyundai Elantra GT: 14.965 @ 96.247
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2011 Hyundai Elantra Limited: 16.910 @ 84.110
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