Hyundai 4g63 Assembly Part 1
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
2013 DSM Shootout - 4G63 BMW drag race - Matt Arruda 9.23 @ 154 mph
Infamous Performance, Matt Arruda in his 4g63 Swapped E30 BMW.
Matt ran a new best in qualifying Round 1 of the Quick 16, 9.23 @ 154.47
Car has a ton more left in it, need to get trans issues worked out.
This was the result of non stop work, many people coming together to make
it happen, and an at the track rebuild of his transmission that same day.
Here is a quote from his post on our local forum about the ordeal starting
at Friday night after having issues on a test pass:
"Back in the pits I ruled out any electrical issues and narrowed it down to
a mechanical issue within the transmission. At this point it was about 10
PM and I had a head ache so I called it a night. Just before I hit the
pillow I got a few much needed phone calls from my trans builder and Bill
Hincher with some much needed words of encouragement. Saturday morning I
got up at 7am and started to removing the transmission with plans to tear
it down to find the issue (mind you i have never disassembled an auto trans
or have any clue of their internal workings) With a small list of things to
check over I got right to it, in the mean time I sent Tom W. to Summit
Racing about 2 hours away with my debit card and no shopping list. I just
told him call m when you get there ill have a list by that time. Sure
enough within an hour with the help of some newly acquired friends Jason
Crooks and Jake Lipton we had the trans torn down and found the direct drum
to have some burnt up clutches. At this time I called Tom and he was able
to pick up a TCI master rebuild kit for a whopping $130 and started to head
back. While waiting for Tow to get back we noticed that the direct drum had
some scoring where the clutch pack floats inside and it was suggested that
we have it machined before reassembly so off we went to the local machine
shop to have the drum cut. Chuck at Wakeman Power machine was more then
welcoming and gave me a super hook up 12 qts of type f trans fluid, 4 cans
of brake clean, 1 tube of ultra black, and machine work for a $38 WOW is
all I can say Thanks Chuck ! Back to the track we went to finish assembly.
Our 1st round qualifier was at 7PM and we just topped off the trans fluid
and jack stand tested at 6:45 everything looked good so we towed the car to
the line just in time and ended up running a new personal best on this very
Even though the rest of the weekend didn't go very good I couldn't be
happier it was truly amazing that our group along with my newly acquired
friends where able to pull this off and for that I'm so thankful to be part
of such a great community."
New England DSM
21st Annual DSM Shootout
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:
There's also this at EvolutionM:
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.
Chick in a Procharged C7 Corvette takes down Viper!
When you bet a sandwich on a race, you better be prepared to pay up if you
lose! This Nitrous Outlet equipped V10
Viper gets taken down at Street Car Takeover OKC in the Drag Strip Roll
Race event by "Miss Stangkilr" in this beautiful Procharged C7 Corvette
The Vette is only making 7psi on a temporary P1SC Procharger, it is around
570whp, the Viper put down 480whp and isn't spraying on this pass
4G63 Datsun 1200 - Jett Racing
Mitsubishi 4G63 turbo powered Datsun
1200 Ute by Jett Racing. Racing in the Pro Compact class at the 2012 Sport
Compact Brisbane Jamboree.
Get your track gear!
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