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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.


 


More Videos...


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.





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.





4g63 Oil Filter Housings
The link to my website is here BUT THE DATA AND PAGES ARE NOW BEING CREATED. I couldn't leave you without a video any longer. I really will have a link here very soon that goes straight to the information. To prove I'm not bullshittin' you... here's the website. http://www.jafromobile.com It's full of placeholders and copy I did not write. Though I did not write it, the author knows me very well! There will be highly-detailed measurements of all the pieces parts available shortly. I suppose if there was anything else I needed to say here it would be... these are the filter housings I got my hands on and tested. They happened to be from each of the models of the mainstream cars with a 4g63 in the United States with only one exception (EVO III). There may be variations from year to year, but to be as specific as I possibly can, read on... The 91-94 housing I demonstrated is specifically from an early 1992 6-bolt/4-bolt turbo AWD car. The one I call 95-99 is specifically from an October '94 built 1995 model Eclipse GSX. One of the '90 OFH's was brand new, and the other one on the Colt came from a 1990 Plymouth Laser FWD. The Galant housing I have no data on. I was told that's what it was. It may actually be from a non-turbo Eclipse? The 1990 factory service manual has an illustration of this oil cooler-less unit. I've never paid attention to this in the junkyard and I haven't owned a NA 4g63. Do the 1g non turbo DSMs even have oil coolers? You guys know better than me. The non-turbo oil filter housing is the least restrictive because it has the longest spring installed depth. The non-oil-cooler blocks are the no-oil-squirter blocks. Get how these are similar? You put an oil cooler on this thing and your pressure goes up. Look at the charts. Put an external air-oil cooler on a 1g? Your pressure goes up. Put the Evo III housing on a 2g? Pressure goes DOWN. High oil pressure can result not just from how you built your motor. Last thing to say... Yes, you could easily INCREASE your spring installed height by using a THICKER crush washer. That would lower your pre-load, opening pressure AND piston travel across the port prior to spring bind. Could you double-stack crush washers? Probably. Will it leak oil? I'm sure it will eventually. Either bore the cap deeper or machine a 1 piece part is my recommendation. Would I try it with stacked crush washers? Most definitely. Look at what you have to do to remove and port it.





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!





4G63 Mitsubishi Powered Mustang - WTF?!
Never would have thought we would see a 122ci 4G63 Mitsubishi powered Fox Body Mustang when we went to Georgia for the LIGHTS OUT V drag race (DVD Pre Order - http://freelifefilms.com/?p=1082) This unique x275 car, built by CDub Racing out of Louisville, KY caught everyones attention at the race just by the freak noise that it put out compared to the rest of the field. Full article on the car - http://www.dragzine.com/news/jesse-abeles-mitsubishi-4g63-powered-fox-body- Mustang-build/





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.





2g 7-bolt 4g63 Engine Removal & Disassembly
Tearing down the GSX to see what broke, and what I need to buy. Sitting for a year and letting the battery drain took a toll on the polished finish... and it looks like a piece of 4th gear wanted to take a look at the outside world. Holy transmission case, and it's off to TRE to see what's salvageable. Looks like the clutch could stand to be replaced, too. Timing belt has taken some abuse from the higher rev limit and I was expecting that. EGT probe is fried and I don't even care. Since I'm running DSMlink and can log Boost, I'm removing all my gauges anyway. Front case seal (freeze plug) is leaking a tad, and the crank seal shows signs of excessive crankcase pressure. I'm going to make some changes... I've got a lot of other tricks up my sleeve, so stay tuned.





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. ;)





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.





4. Tearing down a '90 Turbo 4g63 engine
Decided to rebuild the engine to leave nothing in question.





VR4 Galant 4G63 DSM GT3582 TURBO (PRETUNED) Re-make 650HP AWD 30 PSI
I finally found this video. I messed it up when I first uploaded it ; I hope that I do it some justice this time. This car has been a well kept secret. Full coil-over Suspension isn't dialed in yet either.





三菱 ランサーエボリューション4G63エンジン モンスタースポーツ コンプリートエンジン【MX350】作業解説 [MONSTER SPORT MITSUBISHI EVO TUNED Eg]
http://item.rakuten.co.jp/tajimastore/c/0000000162/ http://www.monster-sport.com/product/parts/complete_eng/ http://www.monster-sport.com/e/car/evo10.html 三菱のスポーツエンジン4G63を、多くのモータースポー 用エンジンに携わり、エンジンの研究・実験により得 ノウハウと、高度に標準化した品質管理と工程管理の でコンプリートエンジン化しました。





6.72 @ 209 MPH - COLLIN WILLSHIRE - 4G63 MITSUBISHI ECLIPSE
Collin Willshire of Jett Racing, today broke the record for Australia's quickest and fastest 4 cylinder powered car with a 6.72 @ 209 mph at APSA round 1.





Cylinder Head 109 - Oil Port Mod
This is a continuation of the deck tech video, but instead of focusing on the deck, this focuses on the oil system and modifications that are necessary if you've had the head resurfaced a couple of times. There are other benefits that can be gained for cars that have no block oil squirters and deleted balance shafts. There are varying degrees of this mod that can be performed for a variety of different configurations, so do your research regarding what you'd need in order to determine how deep you should cut it. Most of the data will be based off of your baseline oil pressure both in the head and in the block. If the block is high, or the head is low in relation to where it should be, then you can benefit from this modification. The most obvious sign of inadequate oil flow would be noisy lifters. Revisit the Deck Tech 103 video for further clarification on casting variances, ARP head studs, machining tolerances, and what all the other holes do.





Cylinder Head 104 - Remove Valves & Springs
Just one of many ways to remove valves from a cylinder head. I haven't seen a valve compressor like this one on YouTube yet. I know it's nobody makes them like this, because this one is a custom hack job specifically for 4g63 heads... but it's extremely effective and easy to use. Since I don't own a valve grinder, valve spring pressure testers (for installed height measurement), or valve seat grinding stones... there are several services I'm unable to perform myself. But since I can get the head disassembled to this state, it would be easier and cheaper for me to have them serviced by someone who does. Valve grinding machine time is cheaper if they don't have to tear down the head. You can lap them in yourself, but if the seat's in really bad shape, it will require attention to allow any of those efforts to be worthwhile. Valve seat grinding if necessary needs to be done with the proper tools, and if the seats must be replaced, then it can get expensive. Usually $20-ish a hole. Sometimes an oversized bore can be cut into a factory seat. I'm ordering a set of valves to see if that's possible.




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