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.

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Jafro's GSX Build Parts - 1gina2g
Some advice and expectations about the parts acquisition process. Cars only get built in a week on TV. And still then you have to take their word for it. The ones that actually do it have a 20 man full-time crew, and therefore; they have no excuse for not having it done yet. We don't have that. Stuff takes time. I'm not building a car to sell it. There's a whole lot of parts in this video. Whole lot of parts. Rather than spend a ton of space babbling incessantly, this is what you came here for. Part numbers. Meat. This isn't an all-inclusive list of parts for a rebuild. It's what YouTube let me fit. I hope you find what you needed. If not, hang tight. Help is on the way. Shoutout to Sirnixalot in the Cayman Islands for this thread about valvetrain part weights: http://www.dsmtuners.com/forums/cylinder-head-short-block/393646-evo3-evo8- valvetrain-weight-comparison-inside.html 6-bolt fasteners: MF140202 - Bolt, Engine RR Plate Flange M6 x 10 (2qty) MD012109 - Bolt, Engine RR Plate Washer Assembled 6 x 16 (2qty) MF140202 - Bolt, Timing Belt Cover Flange M6 x 10 (4qty) MD167134 - Bolt, Engine Oil Pan (2qty) Flange M6 x 8 MD097012 - Bolt, Engine Oil Pan (17qty) Flange M6x10 MD131417 - Bolt, Timing Belt Cover Flange M6x16 MD040557 - Bolt, Flywheel (6qty) M12x22.5 MS401451 - Stud, M10 x 28 Cylinder Block MD065945 - Plug, Cylinder Block Screw (balance shaft) MS240211 - Bolt, Crankshaft Pulley Washer Assembled M8x25 (4qty) MD129350 - Bolt, Timing Belt Tensioner (2qty) M8x51 MD129354 - Bolt, Timing Belt Train M10x33 Happy Face Bolt MF140062 - Bolt, Engine Front Case M10x30 MF140225 - Bolt, Engine Front Case M8x20 (4qty) MF140227 - Bolt, Engine Front Case M8x25 MF140233 - Bolt, Engine Front Case M8x40 MF241266 - Bolt, Oil Filter Washer Assembled M8x65 MF241261 - Bolt, Oil Filter Washer Assembled M8x40 (2qty) MF241268 - Bolt, Oil Filter Washer Assembled M8x75 MF241264 - Bolt, Washer Assembled M8x55 MF140021 - Bolt, Cooling Water Line Flange M8x12 MF241256 - Bolt, M/T Clutch Slave Cylinder Washer Assembled M8x28 MD718549 - Bolt, Transfer Case Washer Assembled M12x130 (3qty) MF241319 - Bolt, Transfer Case Washer Assembled M12x70 (4qty) MD706012 - Bolt, T/M Connecting Flange M8x60 MD108474 - Bolt, Starter Flange M10x65 (2qty) MF140266 - Bolt, T/M Connecting Flange M10x40 (2qty) MD740892 - Bolt, T/M Connecting Flange M10x43.5 MF140471 - Bolt, T/M Connecting Flange M10x65 MD706012 - Bolt, T/M Connecting Flange M8x60 MF140021 - Bolt, T/M Connecting Flange M8x12 6-bolt Rear Main Seal Housing: MF140205 - Bolt, Cylinder Block Flange M6 x 16 (5qty) Rear Oil Seal Case MD040330 - Case, Crankshaft Rear Oil Seal MD040332 - Oil Separator Crakshaft rear oil seal MF472403 - Pin Cylinder Block Dowel 6x14mm (2qty) MD183243 - Gasket, Rear Oil Seal Case 7-bolt Rear Main Seal Case MD172170* * oil separator ring only required on 6-bolt cars, same oil seal, different gasket. Throttle Body Gasket: 8903.1-9006.1 MD125822 1g 9006.2-9207.3 MD146399 1g (AC60-653) 9208.1-9405.1 MD194578 1g 9401.1-9907.2 MD180360 all 2g cars (MD1) Intake Elbow Gasket: 8903.1-9207.3 MD340327 1g 9208.1-9405.1 MD194827 1g 9401.1-9907.2 MD302262 all 2g cars MD307343 - OE Valve Stem Seals (16qty) MD087060 - OE Fuel Injector Insulator (4qty) MD614813 - OE Fuel Injector O-Ring (4qty) MD181032 - Gasket, Exhaust Manifold 1g/2g (standard) MD188995 - Gasket, 1g Intake Manifold MD192031 - Gasket, 2g Intake Manifold MD183808 - Gasket, Standard Composite Head Gasket 89-99 MD069879 - 1g Sensor Coolant Gauge Unit MD177572 - 2g Sensor Coolant Gauge Unit MD310606 - 1g/2g alternator belt 985mm MD186124 - 1g/2g alternator belt 980mm MD186784 - 1g/2g Valve Cover Gasket MD186785 - 1g/2g Spark Plug Well Gaskets (4qty) MN119896 - 1g tensioner arm MD170402 - 2g tensioner arm MD997608 - 1g thermostat kit MD315301 - 2g Thermostat Kit MD141510 - 1g Knock Sensor MD300670 - 2g Knock Sensor MD133273 - 1g/2g Oil Pressure Gauge Sensor MD091056 - 1g/2g Coolant Temperature Switch MD095656 - 6 bolt clutch cover plate MD191171 - 7 bolt clutch cover plate MD178430 - 1g Power Steering Belt MD310617 - 2g Power Steering Belt MD311638 - Oil filter cap gasket MD343564 - Oil Seal, Crankshaft Rear MD030764 - O-ring, Cooling Water Pipe 33.4mm MD375091 - EVO 8 Rocker Arm





6-bolt 4g63 Kiggly Main Girdle Install
Ballos Precision Machine was nice enough to let me into their operations and film the installation of my 6-bolt Kiggly Main Girdle. They let me do this as a gift to all of you. THIS IS NOT THE FINAL INSTALLATION. Though all the parts were cleaned prior to pickup, they will be extensively cleaned again, and the fasteners installed finger-tight with red Loctite exactly 15mm above the surface of the main girdle and torqued in the proper torque sequence. My main caps were level and straight, the crank bore was straight to begin with, and had never been line bored following the original assembly at the factory.





Mitsubishi 4G63 Honing with Torque Plate
See what a difference a torque plate makes on a Mitsubishi 4G63 block out of an Evo IX makes as John Edwards @ Costa Mesa R&D Automotiove Machine walks you through the steps. (949) 631-6376 Don't forget to 'Click' and SUBSCRIBE.





7-Bolt Shortblock Failure - Full Diagnosis
If you are your own mechanic, there is no more important character trait worthy of development than the ability to own your mistakes. That's where the line is drawn between good mechanics and bad mechanics. It's not the failures but how they deal with them that measures their ability. In short, it's not easy to admit you did something wrong or were negligent. But if you don't own it and talk about it, it doesn't get fixed, and nothing positive can come from it. It was my quest to overcome my clutch issue that lead to the creation of a video. That video is the textbook perfect guide for how to correctly install a DSM transmission. https://www.youtube.com/watch?v=6bE_9sWtnSY&list=PL4B97C16D423317DD Crankwalk as described is caused by a casting defect. This was not a defect. This was preventable. A lot of people would find something like this and not tell anyone out of embarrassment. I'm not ashamed. It's my fault. I got good use out of this engine and it was tough enough to make it 48K miles since the last rebuild despite my abuse. I'm here to tell you if you bought a used car that's had its clutch replaced, or if you ever pay someone else to do it... make sure it has this bolt. It's stashed away between the starter and the transfer case, so it's hard to see. Make sure all of your bell housing bolts are torqued properly because fastener problems can destroy your shortblock, clutch and transmission. If your car fails because of a mis-aligned transmission, you have no reason to blame crankwalk. It wasn't until I bought my next AWD car that I discovered there was a smaller bolt on the other side of the block. I destroyed 3 transmissions in the GSX first. With the damage already done to my crankshaft, I then lost a shortblock. It's an ounce of prevention that's worth metric tons on your bank account. Grade 10 M8x60 bell housing bolt = MD706012. It gets 22-25'lbs of torque. Owning my mistake permits me to learn from it through con$equence$, and never repeat it. What good would it have done anyone else for me to learn this lesson and not share it? That's why I'm providing this video to all of you. Sharing it can perhaps help someone else avoid this costly mistake. This is the final chapter for my 7-bolt, and this book is going back on the shelf. Here are some valuable resources if you're trying to read bearing damage: http://www.enginebuildermag.com/Article/5150/csi_engine_bearings_when_good_ bearings_go_bad.aspx http://catalog.mahleclevite.com/bearing/ http://www.studebaker-info.org/tech/Bearings/CL77-3-402.pdf And of course, now that I've covered the complete oil system, transmission and driveshaft series of videos, you now have all the tools necessary to ensure your 4g63 lasts a very long time. Whether the casting defect exists?... or it's all caused by a bolt, or the harmonics, or whatever... Sure, crankwalk exists and it's horrible. But with the small amount of movement required for your crankshaft before it contacts the block isn't far enough to make your clutch drop to the floor when you turn. You'd be hearing woodpeckers and jackhammers on the crank long before that clutch pedal would fall to the floor. Some people are going to hate on me for saying that. That's fine. I believe all of the people who experienced the clutch pedal issues had fastener problems on their bell housing. DSMs get a bad reputation for this but we can change that. Crankwalk is never the cause of your engine failure. Crankwalk is always a symptom of the real problem. It's your disease that makes you deny it's your fault. You've got the 'itis. DSM-itis. Whenever you dig deeper, you'll discover what applied all of those thrust loads to your crankshaft to begin with, and it's not going to be a casting defect that moves your crank .101". Mine only went .014", but all of the same parts failed. PLEASE tell me in the comments if you find this bolt is missing from your car.




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