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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)


 


More Videos...


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.





DSM 4g63 Engine Build
This is the video I made for the rebuild I did on my 1995 Eagle Talon TSi AWD. It took us over 6 months of hard work consisting of many almost sleepless nights, and countless frustrating moments that almost made us walk away. Engine Work Includes: honed cylinders, decked head and block, head rebuilt, new timing components, water pump, arp main and headstuds, acl race bearings, cometic mls headgasket, new engine gasket set, stock pistons and rods, odds and end stuff.





4G63 removal
this is the progress i have made on my talon in the last 5 months





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. :)





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.





1991 GSX rebuild
Rebuilding my 4g63t dsm





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.





How to remove Valves on 4g63
The easy/fast way!





lancer evo build 4g63





4G63 Dragster - Startup
We put the turbo on and got the TPS fixed so we could rev it up some. Enjoy!





turbo4.com 4G63 Dragster - Engine View
Here are a few new camera shots from our Go-Pro camera. We'll be posting new views of the car with this camera in the coming months.





Cylinder Block Machining Video - Engine Building DVD
Buy the "Basic Engine Building" DVD http://store.boxwrench.net/Basic-Engine-Building-DVD_p_8.html Basic Engine Building DVD - Chapter 25: Cylinder Block By this time your block is disassembled and in the machine shop. One of the most informative sections, here we take you behind the scenes to show what goes on while your away. We show the process of align honing the main bearing bore that is needed before anything else can be machined. Then the block deck is leveled and machined as needed for the new head gaskets to seat properly. And finally the cylinder walls are bored out just shy of their new size, which will be achieved when they're honed. BoxWrench.net is a community and resource designed for automotive enthusiasts. The Basic Engine Building DVD is over three hours of engine building that covers everything from removal and disassembly to final assembly and engine start-up. This is the ultimate DVD for any home mechanic or engine enthusiast that wants to see a complete rebuild from Teardown to Start-Up. This video can be used to learn how to work on almost any type of internal combustion engine including V8, V6, Straight 8, in-line 6 and even 4 cylinder engines. All of the interactive features and menus will not work over YouTube. This video is great for people interested in car repair, car care, and restoration. As well as hot rods, muscle cars, performance parts, and Boosting horsepower. It can also help you to gain knowledge for increasing fuel economy, how to lower your emissions, and covers preventative maintenance to avoid little things like overheating. Get the full DVD with all of the interactive menus, Tools section and engine Glossary terms here... http://www.boxwrench.net Educating the Automotive Enthusiast! Don't forget our Holley Installation & Tuning DVD. Sample clips on our youtube page and at our store here... http://store.boxwrench.net/Holley-Install-Tuning-DVD_p_12.html BoxWrench on Facebook: http://www.facebook.com/boxwrench





Edelbrock RPM Olds 455 Head Porting
The scariest thing I ever did was port a set of new Edelbrock aluminum cylinder heads. My first attempt at porting any cylinder head. I raised the roof .200" and dropped the floor .040". It's best to leave the floor alone or raise it by filling with epoxy. Porting kit by Mondello.





4g64 DOHC Build-up
Here's a short video of my 4g64 with 4g63 head Build-up. I still need to tune the motor a little as you can see or hear in the video, the motor sounds a little rich specially after 7000 rpms. Dyno video coming soon... Hope you liked it..





2.3L stroker dsm eclipse gst build
2.3L stroker eclipse finally coming alive





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