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Blueprint 102 - Measuring 4g63 Crankshaft Endplay

4g63's are famous for hosing crankshaft thrust bearings. This video illustrates the process of how to check the thrust bearing clearance whether the motor's in the car or not. Of course in my case the motor's on a stand for this video. Lucky for me! In cases where the engine is still in the car, the same procedures can be used so long as the indicator is attached to the engine block. The plunger can be set up touching either the inside of the crank pulley or by removing the clutch cover plate and contacting the flywheel. What the thrust bearing does, is prevent the crankshaft from having lateral movement in the main bearings. If a crankshaft develops excessive movement here, clutch engagement and hydraulic problems will begin showing up, followed shortly thereafter by catastrophic failure of main bearings, rod bearings, connecting rod failures, oil pressure problems, or even broken blocks, crankshafts and rods in extreme cases. It's important that every 4g63 turbo engine is within spec on this measurement. When the crankshaft aggressively wears through the thrust bearing developing lateral play, this is called "crankwalk". On some block castings, replacing the bearings will NOT fix the problem. An engine block that is prone to crankwalking can not be fixed. The only option in these cases is to replace the shortblock and rotating assembly with new or used parts that are stronger than the one you've unfortunately encountered. For the 2g guys, the best option for repairing this problem is to remove the 7-bolt turbo shortblock your car came with and replace it with a 6-bolt from a 89-92.5 production date turbo DSM. Non-turbo blocks CAN be used; however, the block will not have oil squirters that aim towards the back of the pistons. That stream of oil aides lubrication to the wrist pins, cylinder bores, and somewhat cools the pistons. All good things on a turbo setup. Aside from that difference, there are no other differences between the non-turbo and turbo blocks. The pistons and thus the compression ratios are different, but that's it. Oil squirters can be machined into the main galleries of a non-turbo block, but it's more trouble than it's worth unless you can't find a turbo block. There are tons of differing theories about what causes crankwalk. Nearly all of them are plausible and logical arguments. I will not get into those debates in this video in order to focus on procedures for testing and replacement. Please feel free to google "crankwalk 4g63" and read the volumes of information available already. The arguments and gathered data are older than the Eclipse itself and in abundant supply on the internets. Magnus, RRE, VFAQ, and many other parts vendors have lengthy write-ups on their own research and development. The bottom line is that the 6-bolt shortblocks are LESS likely to suffer from this. Next time you see someone with a video that looks like it was shot with a potato asking "does this sound like crankwalk", you can send them this video. There's a reason for every noise, rather than focus on the sound, focus on eliminating the real problem. KNOW if it's out of spec.


 


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Cylinder Head 105 - Valve Job Basics
Valves not sealing? Valves not bent? This is how you fix that problem. In this video I outline the basic valve job procedure. Cleaning the valves, cleaning the seats, cleaning the combustion chamber and lapping the valves in to make a better seal. Here I cover the process start-to-finish. It's the same exact process for pretty much all non-rotary combustion engines. It takes patience and perseverance to do this job, but anyone can do it. Reference your service manual for measurements and service limits. Everything else that's not in your service manual is in this video. I apologize for not having broken busted crap to work with in this video. It's more beneficial to all of you when bad fortune falls on me because it gets well documented, and many people watching these videos are looking for answers. If you have bent valves, you will discover it quickly once you chuck one up in the drill. You'll see the face of the valve wobble around while it spins. You'll see evidence of this damage on the valve seat. If it's bad, you may see damage on the valve guides in the form of cracks or missing pieces where the valve guides protrude through the head ports. Give all that stuff a good visual inspection. ...and if you doubt yourself, never hesitate to get a second opinion or consult a machine shop. They will have access to expensive tools that you wont find in your average gearhead's garage.





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.





4g63 Balance Shaft Elimination - bearing modification
This is the first part of a two part series about balance shaft elimination on 4g series engines. This video details the bearings, the other video will cover the front case modifications. I've already got a low-def video of the front case mods, and I plan to re-shoot that one in HD when I'm in the assembly phase. It's linked in the video. The balance shafts are designed to cancel out harmonic vibrations caused by combustion and the spinning rotating assembly. They may offer a greater degree of comfort to the driver and passengers, but with that comfort comes a price. Often, when a 4g63 timing belt gives up, it's because the balance shaft belt breaks or comes loose and takes the timing belt out with it. When that happens, it can total your pistons, valves, damage the crankshaft, wrist pins, timing belt tensioner and crank angle sensor. Basically, it can total your motor. The balance shafts also have a combined weigh over 10 lbs and both are driven off the timing belt making them additional and heavy rotating mass. If you've got a lightweight flywheel but still have balance shafts, you have your priorities mixed up. So here's what you do with the bearings. It's easy. You can do this at home. You CAN do it with the motor in the car, BUT DON'T. You must enjoy punishment to do this like that. The end result will slightly increase your oil pressure, but usually not enough to cause concern unless you have a full-circumference bearing turbo, ball bearing turbo--with your oil feed coming off the oil filter housing. The head feed would be better in that case because it's regulated at 15 PSI.





Calculate Your Compression Ratio
This is everything you need to do to calculate your compression ratio. No foolin'. Every equation and process demonstrated. Find all your variables. Know your exact compression ratio in every cylinder. This is how you do it. Just because your service manual says your car is 7.8:1 or 8.5:1 compression doesn't mean that it is. Whenever there are casting irregularities, variations in piston height, parts that have been machined, non-OE parts, or changes to your head gasket selection, your compression ratio WILL change. It's highly probable that you're only CLOSE to spec if you've never touched your engine at all since it was "born", and that it doesn't MATCH spec. Even if it did, how would you know? This. 5 variables. V1 Swept Volume V2 Deck Volume V3 Piston-to-deck clearance V4 Piston dish cc's V5 Head combustion chamber cc's The ratio math: V1+V2+V3+V4+V5 = volume of combustion chamber at BDC V2+V3+V4+V5 = volume of combustion chamber at TDC The ratio is... (V1+V2+V3+V4+V5) ÷ (V2+V3+V4+V5) : (V2+V3+V4+V5) ÷ (V2+V3+V4+V5) or BDC ÷ TDC : TDC ÷ TDC First you fill in the variables, then you calculate volumes, then you add the volumes, then you reduce the ratio (fraction). It's that easy. Here are your magic numbers: 0.7854 = Pi quartered to the ten thousandth 16.387 = number of cc's in a cubic inch. If you divide any number in cc's by 16.387 it gives you inches. If you multiply any number in cubic inches by 16.387 it gives you cc's. Quartering pi lets you use the calculation: BORE x BORE x STROKE x .7854 = volume of a cylinder instead of... π x (BORE ÷ 2) x (BORE ÷ 2) x STROKE = volume of a cylinder Either way is right. You get the same result if you calculate pi to the ten thousandth. While I apologize for all the math, no I don't. I'm really not sorry. You actually clicked here for it whether you realize it or not. This is ALL the math, the tests, and the whole process to calculate your cylinder volumes and compression individually even if you don't know any of your variables yet. All of my numbers are present for those who want to calculate out the last 3 cylinders out of curiosity just to see how it affects cylinder volumes and compression ratios from one cylinder to the next. Why would I do that for you? Why would I deprive you of that practice? Just assume that all 4 of my combustion chambers are 41.75 ml if you do this. Clicking like share and subscribe helps a channel grow. It also motivates me. Don't sweat the camera. It's enough to know that so many of you care about what I'm doing here. From the bottom of my atmospheric dump, I thank you all! This gift horse's teeth are all over the place, but he sometimes poops gold nuggets. PS: Use ATF for your piston dish volume tests, not alcohol. Of course it's better just to use the spec sheet included with your pistons... but not everyone gets that luxury. Water is just fine for head combustion chamber tests. Dry and re-oil all parts that water touches.





Cylinder Head 205 - Degree DOHC Camshafts
This video is all about establishing your valve timing baseline, and adjusting your camshafts to the manufacturer's spec. It's only ONE of several steps that should be performed when you're assembling your engine on an engine stand. Establishing these conditions with accuracy while your engine installed in the car is a near-impossibility, and the reason why... is demonstrated in this video. There are several challenges to overcome when performing these procedures on a 4gxx series Mitsubishi engine, and they're all defeated here. The cylinder head used in this video is a J1 spec '92 Hyundai Elantra small-combustion chamber head which has had several valve jobs and has been resurfaced multiple times by budget engine remanufacturers who didn't care about quality control, as well as performance shops who do. It has had no less than .040" removed from the head gasket surface, the valves are recessed because of all the valve jobs performed, and at some point when it was cut, it wasn't level. Removing material from the deck surface will change the installed camshaft centerline, and that will change your engine's valve timing events even if all other parts remain the same. I would claim this is a multi-part video except that I've got the videos broken up by topic already, and this one is all about setting your cams to the manufacturer's specification. It is not the end of testing that will be performed with these tools. The basics concerning the process and tool fabrication are covered here. Further discussion on this topic concerning the effects of advancing or retarding camshafts from spec, and for checking your valve clearance will be in the videos that follow. I had to end this video after the manufacturer's spec was achieved to make it easier to digest, and because it would have created a video greater than one hour in length despite the break-neck speeds that things happen here on Jafromobile. Where your cams are set determine how the swept volume of the combustion chamber gets used. The information on the manufacturer's spec sheet is their recommendation for baseline settings that will help you get the most out of those camshafts. Whether or not your engine can operate with those specifications without additional hardware or without causing a catastrophic failure will be expanded upon in Cylinder Head 206. The next video should be used as a companion to this video because establishing the manufacturer's baseline is not the end of the assembly or testing process. It's only half the battle. Should you be lucky enough to find your combination of parts allow your camshafts to fit and requires no additional adjustment after assembly, the steps in this video and in Cylinder Head 206 should still be performed if you are doing the assembly yourself. Failure to inspect these variables may lead to a tuning nightmare once the engine is back in the car, hard starts, or worse... bent valves and damaged wrist pins. Making these tools and performing these steps will give you the peace of mind to know with certainty that your engine is operating safely at its peak performance.





Cylinder Head 106 - Casting & Porting Tech
Description. No really guys, what can I type here? I just went on for 18 minutes without shutting up. I apologize for deviating from my normal format, but we're almost there... ...when I port a head, there will be no voiceover, and it will be a 200-series video.





How to Assemble a Chevy Engine Part 1
This video will show you how to assemble a Chevy engine (or any engine) starting from the basic block. It goes through installing the crankshaft, checking for the right clearences using plastic gage, installing the rings on the pistons, installling the piston in the block, checking the rod bearing clearence, torquing all the bolts to the collect specifications, installing the rear main seal, and demonstrating how the motor works from the bottom view and top view.





Glyptal Application Process
In this video I detail the application process of a popular crankcase coating... that is... if crankcase coatings are actually popular. In this video, 98 coffee filters gave up the ghost. 238 q-tips paid the ultimate sacrifice. Almost a dozen brushes were executed, and 3 aerosol caps dispatched to their graves. Also, during the battle, several Dremel tools were maimed, one severely. Look, I'm doing everything I can to liven this topic up and make it interesting. Cleaning and painting are about the least interesting things someone else can watch. It's absolutely painful to edit, I know that much. It's not so bad for the guy doing the actual painting, but I'm doing my best to keep people's attention. This is a full month's work in a half hour. I had to space the job out because of my filming environment and the toxicity of materials I was working with. Take my warnings and advice in the video seriously. They're the words of someone who's done the job. They help set expectations. The most useful thing I can do is post links to other discussions that have already occurred, and to make room for places where people have posted their experience with failures of engine coatings. Despite my searching, I can not find any pictures or video. I found ONE plausible description of the kind of failure that can occur with improper application, but it was still a third-hand report. There are fans of this product posting in these threads. If you are considering this treatment, WEIGH THE PROS & CONS FOR YOUR BUILD, and YOUR HEALTH. Don't do this just because I did it. So until anyone provides photo or video evidence, here are the links to threads where it was discussed. This google search is mean. It's too direct and to-the-point. It might hurt somebody's feelings? Yes, I've read them all. http://www.google.com/search?client=safari&rls=en&q=glyptal+caused+engine+f ailure&ie=UTF-8&oe=UTF-8





How to polish a crank ( crankshaft )
Engine-Guru.com Presents a video on how to polish your crank shaft. Any questions call 616-430-3114 ask for KYLE. We are located out of Grand Rapids ,Michigan.





Hyundai 4g63 Assembly Part 3
I have bad news. The big camera's playback heads bit the dust from extensive prolonged use. I wore out the tape drive. No manner of cleaning tapes can fix what it's been through. I've talked many times about how much footage goes into one of my 15 to 30 minute videos, and for every hour of video footage I've shot, the camera does double-duty because after shooting, it has to be played back in real time during capture. I've done more than 130 videos this way, probably over 2000 hours of use in the harshest of environments, and it just couldn't handle it any longer. I shot several more tapes beyond what's in this video that I can't even import because the play heads failed. I don't know if any of that video even stuck to the tapes? The lost footage from the last video was an early and un-recognized sign of what was soon to come. I know I joked about it, but in reality it's really not very funny at all. I can't afford a backup for a piece of equipment like this, so it's something I don't have. As bad as this news might feel to you, I feel it 21,000 times over and I mean that. This couldn't come at a worse time and expense for me, and at a point where my production was really starting to wrap up on this project to move on to bigger and better things. It's the only camera I have that can do what I do here on this channel, so I'm forced to stop production for now. Even though my camera is huge, 7 year old HDV technology, these things still sell for several thousand dollars used because they record un-compressed video unlike every other flash storage based solution available at twice the price. 3CCD 1080/60i HD cameras that shoot to tape have advantages that you can't affordably achieve with solid-state media. I have to use un-compressed footage to do what I do here or else there's nothing left of the video quality after 7 exports and a final mpeg compression. The Sony Action Cam can't do it, we learned that in a previous test video. Even if it could, it can't do close-ups and everything's fisheyed. Buying a low-end 4K camera is impractical because I can't efficiently or effectively edit that video without a $9,000 computer. Jafromobile is just not that big of a channel, and I do this completely un-sponsored and at my own expense with the help of a handful of friends who volunteer their talent, time and information. It's the epitome of low-budget and what it earns still doesn't come close covering the channel's equipment and expenses as they occur. People have urged that I do a kickstarter, but I can't bring myself to ask for that from the community. I don't sell a product or offer services so there is no profit margin. I can't accept money for something that happens only at the speed of my available resources. To me, this channel is my proverbial gift horse to all of you. http://en.wiktionary.org/wiki/don't_look_a_gift_horse_in_the_mouth I know what you're thinking and I realize this is a grim conclusion to this video. It sounds like I'm down for the count, but don't rush to the down vote button just yet. As of the upload date of this video, I'm paying out of pocket to fix a ridiculously expensive 3CCD 1080HD broadcast quality video camera so that these projects can resume, and so that I can bring the final assembly steps to you in the same quality you've grown used to seeing here on Jafromobile. If I wear out a camera every 3 years, then so be it. This is love, and no expense is too great. The big camera is being fixed by its manufacturer, and I'm expecting the repair to cost as much as replacing it. I sincerely hope that's not the case. Hopefully my production only has to take a short break. Once production resumes and I can import these tapes, I've got some really awesome stuff coming up and I hope every last one of you is here to see it. I may have a few other backlogged nuggets I can upload, and as always I'm happy to discuss this in the comments and provide updates on the repair as I get them. Update: Awaiting quote due by 5/16 according to the repair agreement. 5/9/2014 9:17:00 AM DELIVERED NEWPORT NEWS, VA US 5/9/2014 5:36:00 AM DESTINATION SCAN NEWPORT NEWS, VA US 5/9/2014 12:04:00 AM ARRIVAL SCAN NEWPORT NEWS, VA US 5/12/2014 - Repair paid in full $440. Far less than I was expecting. I'm glad they still make parts for 7 year old professional equipment. Thank You Canon, USA! Repair should be complete within 7 business days from receipt of payment. The quote only took them 24 hours and they quoted a week just for the estimate, so at this rate I should be back up and running once again very soon. Thank ALL of you for your kind words, HUGE generosity, and all of the moral support. I swear I have the best subscribers on YouTube!





Crankshaft Refurbishing
Many of you have seen this one before. I apologize if bringing it back offends anyone. Domestickilla gave me a crankshaft, and it's a nice one that I want to clean up and use again. You'll be seeing a lot of it and because of this, this video deserves to be here. I fixed what I broke, and this was my experience. In this video Ballos Precision Machine demonstrates magnetic dye penetrant testing, crankshaft polishing and inspecting the balance of a "butchered" 4g63 6-bolt crankshaft.





Hyundai Assembly 4 - Balancing Rods
I edited this video to its finished state, and RojoDelChocolate handed me a track with no collaboration that was the right length and rhythm. I literally did nothing to the video once the audio track was dropped in, and that's just how it went. I can't believe it. It's like when you're pumping gas into a Ford F150 full-blast and release the pump handle to stop right on $80.00 even. He's got more musical talent in his pinky fingernail than I have mechanical ability in my spleen, appendix and tonsils combined. Thank you RojoDelChocolate. Here I'm cleaning up the fly cuts, balancing the piston and rod assemblies and preparing to double-check my valve clearance. I had to start by cleaning up and re-lubricating every part that was removed to prevent contamination of the assembly. This is the tedious part of doing the job right. We learned that this whole engine assembly was pretty far-gone in previous videos, way past its service limits, so making it fit and work again takes extensive testing, machining, and re-testing to ensure all of the parts fit. This is likely the most challenging build I will perform on any car in my driveway. It has been so far. But because I have not demonstrated the basics of engine balancing beyond what a machine shop has to do to zero balance a flat-plane crankshaft, I thought I'd give it its own video right here with one of the test assemblies. When you balance rods by themselves, you balance the big-end and the pin-bore separately. You get weights of both ends of the rod using a jig and a process that I don't demonstrate in this video. The reason you do this is because the position of the weight behaves differently relative to its distance from the crankshaft pin. Weight on the big end has less of an effect than if there's extra weight on the pin bore. The best balanced engines have every part of the piston and rod assemblies balanced separately within .1 grams using the method I just described, and not the method shown in this video. The method shown here involves weighing ALL of the piston and rod assembly components together, and then taking out the difference just on the casting lines of the connecting rod. They were already off-balance and had never been balanced before. This is an improvement, not perfection. It's still something this engine needed to have done. I'm not using the big-end/small-end method here because these pistons are pressed-on and if I try to remove them from the rod, it will shatter the piston skirts. No thank you. I'm not replacing these pistons. The reason I grind down the casting lines is because it's weight is in a neutral territory, extending from the big end to the small end. It's easier to take an even amount off when you grind across the entire length of the rods. This method leaves a lot up to assumption as there's no way to determine which end of the rod is heavier, or if the weight is in a wrist pin or piston. All this does is ensure the crankshaft is spinning an even amount of weight on all 4 of its rod journals. Grams of weight turn into pounds of force at idle speeds. My goal is to remove that vibration at any and all rotations per minute if I can. So I make them all the same within 1.0 grams of their combined weight. If you're assembling and balancing all NEW parts, not parts that have worn together and need to go back in the same holes... you will have to balance the individual parts and pieces. This is the poor man's method. Even with the new parts you still do the poor man's method once you're done balancing the individual parts and assemble them, but sometimes when you're lucky with the new parts, you can just swap around the rods, pins and fasteners to balance the weights on each assembly and not have to grind anything at all. That's awfully nice when that happens. You know the Hyundai won't let me get away with that. Removing stress risers might help strengthen the rods, but it's not what I'm after here or else I would have removed the whole casting line from all of them. These rods should be fine for my goals. My goal is to remove just enough from all of the fatter rods (weight wise) to match the lightest one. Balancing an inline 4 engine with a flat-plane crank is easy if you have already balanced the crankshaft. This crank was already balanced for the GSX motor on a previous occasion. It's zero'd out. In order to balance the rotating assembly, all you do is make the piston and rod assemblies weigh identically to its neighbors. Just 3 grams of weight can produce over a hundred pounds of lateral forces at red-line so this is an aspect of engine building that you should not overlook. All you need to do is get all of them within 1 gram. The scale I'm using measures whole grams, so that's all I can do anyway. This method is acceptable for balancing a rotating assembly as long as you're smart about how to remove the weight.





6-bolt 4g63 shortblock rebuild parts
I'm saying it right up front. This video goes above and beyond shortblock rebuild parts for a reason. Read on... The first part is stern, the last part is happy. Nobody in their right, left, forward or reverse minds puts a 23-year-old 4g63 engine back together with 100% OEM parts. Nobody's shooting for that good ol' stock 190hp feeling with a DSM drivetrain. Nobody. Not unless they've got something to prove. I am putting a 7-bolt head on a 6-bolt block. So with that said, I show several over-the-top internal parts that are and are not related to the short block itself. I show cams and valve springs which only matter for head work. Not part of the short block. Nobody makes an engine gasket kit with all the parts mixed and matched to do this. So what people have to do is order both kits, or order all the individual parts separately like I am doing here. It's at this stage you are working with a machine shop to return your old worn-out block to the specs you've chosen to follow, and you need these cylinder head parts at this stage of the game to do it right. These parts making an appearance in this video show 3 things... 1) I am not aiming for a stock build 2) Now is the time to have your cam and valve springs if you're going to make any changes to the head. 3) these gaskets, seals, pins, bolts and bearings are things you will need no matter what it is you're building if it's a 6-bolt block. When I do the head series, I will be showing modifications and parts to rebuild and make a 7-bolt head fit a 6-bolt block. This video assumes you disassembled a running or freshly-broken engine and that YOU HAVE ALL THE BOLTS, NUTS, WASHERS, and HARD PARTS of the motor that it needs, bagged and tagged like was demonstrated in the "Crankwalked?" video. You've watched me clean and inspect valves, lifters, rockers, crankshafts, rods, etc. I don't need my turbo, hoses, vacuum lines or anything like that yet, and they likely won't be for a MHI turbo anyway. This video focuses on the gaskets, seals, bearings, consumable and disposable parts that you should replace for the shortblock only. My old trusty 6-bolt front case is coming up in a future video, getting refurbished and rebuilt, and ssembling a shortblock doesn't require having timing components yet. The head gasket will probably get its very own video just like the front case. As you can see, I have very big plans with this upcoming series. We've hit the 200's on engine stuff. It's a milestone. For you 7-bolt guys... bah! I know this is all 6-bolt part numbers. Some parts are interchangeable but I didn't make it clear which ones are in this video. Don't worry, you will need these part numbers eventually (I hope that was a joke). But if you wait long enough, perhaps I'll be re-assembling a 7-bolt again? Here comes the first bit of good news... The reason the "Crankwalked?" video had a question mark in the title is because I wanted to see others' comments about it. Gain a consensus. There are so many different opinions about shortblock failures on the 2g cars that I didn't want to take sides with such an entertaining video. But it's not crankwalked. What you see is rod bearing failure as a result of torsional stress on the crankshaft. It was caused by a catastrophic clutch failure. The thrust bearing was .014", and crankwalk cars that fail from crankwalk are usually around .075"-.150". My thrust bearing was beat to death as my old 6-puck fragged. All the fail was initiated by the drivetrain, and the drivetrain problem was a fail by yours truly that had repeated several times prior to me making videos about it and getting it right. It's my fault for not catching it, but when I discovered it, the drivetrain series was born. So my 7-bolt crank is trashed, but the mains are fine. New bearings and a crank would fix its thrust measurements and I may just rebuild it for the sake of a video someday. Now comes the really good news. My brother is working with me to build a website. There will be tech links and things that simply can't be delivered on YouTube. Not in a practical and effective way anyway. Things like schedules, projects and mod lists, parts lists, bolt lists, torque specifications, printable worksheets for blueprinting, the parts I used to make my fuel injector cleaner... stuff my viewers need or ask for. Soon you'll know where to find it. I need to learn how to maintain it, but I'm a good student. Still, these things take time, and I haven't yet wrapped my own brain around its potential. I'm putting it out there for you guys because you deserve it. I'm simply astonished at how the channel has grown, and I feel the need to give back.





How to port and polish a turbo exhaust housing
I'll fill this in later. The "book" I typed in this field before didn't save. Come back later if you want to read more about the theories behind porting and polishing.





4g63 Oil System
This is another installment about 6 & 7 bolt 4g63 oil systems. It's where the oil flows and when. If you see signs of oil starvation on engine parts, it's important to note what is up-stream and down-stream from it in the oil supply. Knowing where the oil flows helps you determine what went wrong. Chasing damage up-stream on the oil system can reveal defects, stuck oil squirters, failed bearings or blockages in the oil galleries. It can also reveal perfectly good parts which means you've gone too far looking for the problem. This is how you determine what really failed, and why it's important to consider how tight or wide to set your oil clearances, and how popular modifications can affect your oil system. About the charts... keep your pants on. I will make them available. Until then, they're right here in this video. ;)




Which car is faster? Which Car is Faster?





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