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4G63 back from the ashes---First half of engine rebuild

After over a YEAR of promises that I'd get this vid done, I went halfway and got the engine pull and most of the shortblock work edited and documented. Here for your viewing deliciousness is PART 1! (link to torque specs for the engine here: http://bit.ly/17KDEED)


 


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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.





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





4g63 rebuild
My Galant and the process of rebuilding its engine





Cylinder Head 108 - 4g63 Rockers
Cleaning and inspection of 4g63 rocker arms. Part 8 of the head series, and probably the easiest one yet to either watch or perform. No precision measurements required, no disassembly or special tools required. If you've got an air compressor and a pick, and a little bit of patience, you can do this part of the job without expending any major effort. This is one of those things that during the course of your build, you can do unconsciously. You just need to soak them, poke them, and inspect them. In this video I show you how. Some parts of the wheel Mitsubishi didn't want to re-invent each time they developed a new motor. These rocker arms are prevalent in millions of Mitsubishi, Plymouth, Chrysler, Dodge, Eagle, Hyundai and even some Kia engines. A good rule of thumb is... everything with a 4g6x DOHC or 6g72 and 6g74 engine uses these rocker arms. From 4x4's to economy cars, these parts are everywhere. You just need to know what cars they're in and you can harvest a full set for a fraction of the cost of one of these things new. If you watch this video, you'll see how to pick a winner. Check this link for 6g7x donor cars. http://en.wikipedia.org/wiki/Mitsubishi_6G7_engine I didn't really want to see any of my rockers damaged, but really I'm lucky some were because it gave me an opportunity to show you some bad ones. Mine suffered from oil starvation caused by rod bearing failures. That loss of oil pressure in addition to oil passages being blocked quickly took a toll. Just 5000 miles earlier I changed to 3g lifters and they were all fine, so this happened quickly. HKS 264/272 cams didn't help anything once the oil supply was compromised, but this was discovered before a more expensive failure in the valvetrain could develop. Remember that sharing is caring. Hit the like and subscribe buttons because YouTube shows all of us a little more love when you do. :)





How to Rebuild a Turbo - Part 1 of 2
Rebuilding a td05h 16g turbo. This process can be applied to many journal bearing turbochargers. :) It definitely comes in handy to know how to do this when you are in this type of hobby. 4/25/12: Small explanation on the balancing of the rotating assembly since I get so many comments regarding it. This particular turbocharger, td05h, has its rotating assembly components balanced separately. This means each individual part (compressor wheel, turbine wheel/shaft) gets balanced separately. This allows for easy interchangeability of parts in case they need replacing. This is why I am able to install a td05 20g wheel on this turbo without having to balance the entire rotating assembly. THIS IS NOT THE CASE FOR ALL turboS OUT THERE. You need to research whether your specific turbo (if it's not td05h) was balanced as an assembly or "component balanced" like I explained above. I hope this information helps. Good luck in your projects. Stay Boostin' keywords: turbocharger dsm eclipse talon awd gsx tsi fwd gst mitsubishi evo evolution lancer 14b 20g td06 td06h td05 install installation upgrade race vs Boost supra wrx sti toyota subaru Dyno laser rs rst 13g hx35 hx40 holset 18g 25g sbr t25 stock replace rebuilding big large nissan 240sx t28





Blueprint 104 - The Crankshaft
It's important to know what you've got even before dealing with the machinist. If you want to inspect a crankshaft, this is how you do it. I detail the process of removing the crank and what to measure. All specifications in this video are illustrated with a 6-bolt 4g63 turbo block, but are all actually the same for 7-bolt engines with the exception of the rod widths.





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.





V8 AMG - engine building process





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.





The Worlds best car tuning disasters and engine failures II - Caught on tape
Wow its tuning disaster II Time More of the webs greatest tuning and high performance engine failures -- you can push and you can push your tuning, but sooner or later some things gonna blow Top 30 all-time tuning failures - close your eyes and watch through your fingers this is very scary stuff, more breaking engines and bank balances. www.viezu.com ECU remapping and car tuning at its best. Car tuning training, software, tools and equipment. Whatever your tuning needs we are here to help. Insured, guaranteed and custom tuning for over 3000 different vehicles, tuning for power, performance, fuel economy, motorsport and carbon reduction -- Tune with the best and mail us at info@viezu.com. For all car tuning training, ecu remapping and car tuning courses and classes see our technical academy www.remap101.com





4G63 Block Resurface
Here's a 4G63 Mitsubishi block on the resurfacer at Costa Mesa R&D Automotive Machine. www.engine-machining.com (949) 631-6376





GST story 2:stroker story 4g63 eclipse mitsubishi 2g 2.3 swap
Started out with a 2.0 4g63t w/ 1G head swap. Did a 2.3 stroker rebuild with a forged Eagle 100mm stroker crank, Wiseco pistons, eagle h-beam rods, MLS head gasket w/ 1G head built with Ferrea comp. series valves, bc dual springs w/ titanium keepers, upgraded lashes and 3 degree valve angle job. Greddy timing belt, stage 4 clutch, fidanza 8lb. flywheel, mishimoto radiator, OBX headers with T4 turbo. Intercooler w/ 2" polished aluminum piping + BOV. Also rebuilt my F5m33 transmission with new gears, synchros, bearings and OBX LSD differential!





DSM Sleeper Rebuild Begins
Quick video of the beginning of my rebuild. **This car has been sold for a while now and my current project is a 1g AWD DSM.Check out my NEW Videos!!**





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.





4G63 Dragster - 7.77 at 171 MPH
Only the 5th full pass down the track for the car and we broke into the 7's! This pass was at 36 PSI. The only changes since the last pass were a fresh set of plugs and we tweaked the tune a bit.




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