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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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THIS IS HOW AN ENGINE IS ASSEMBLED





Danny's 4G63 Engine Build Part 1
Building of a 4G63t engine. Still in the works, so as I make progress, I will continue to add to the video.





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.





Building a 4G63T Engine in 10 minutes
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CRANKWALKED? 7-bolt teardown 1080HD
Now this is a story all about how My bearings got flipped-turned upside down And I'd like to take a minute just sit right there And tell you how I used to mix and burn my gas and my air. In RVA suburbs born and raised On the dragstrip is where I spent most of my days Chillin out, maxin, relaxing all cool, 'n all shooting some BS outside with my tools When a couple of guys who were up to no good Started running races in my neighborhood I heard one little knock and my rods got scared And said "You put it in the garage until you figure out where..." I Begged and pleaded that it not be that way, But it didn't want to start and run another day. I kissed it goodbye, because the motor punched its ticket I got out my camera, said "I might as well kick it." Crankwalk yo this is bad Drinking metal shavings from an oil pan. Is this what the rumor of crankwalk is like? Hmm this won't be alright But wait I heard knocking, grinding and all that Is this the type of failure that should happen to this cool cat? I don't think so, I'll see when I get there I hope they're prepared for this video I share. Well I pulled all the bolts and when I came out There were chunks in my fluids in the pan and they drained out I aint all depressed cause I seen this before. I got my books and my wrench and we'll do it once more. I sprang into action like lightning disassembled I whistled while I worked and my hands never trembled If anything you could say that this bling is rare, and when I saw what broke I stained my underwear. I turned off the air compressor 'bout 7 or 8 And I yelled to crankcase "Yo holmes, smell ya later" I looked at my internals they were finally there To sit on my workbench and stink up the air. Audio track by RojoDelChocolate. Here's the 48,000 mile-old 7-bolt I blew up summer 2011 after over 150 drag passes, a half dozen Dyno sessions, 4 transmissions, 3 clutches and 10 years of hard all-weather use.





6 bolt 4g63 in 2g Eclipse GSX cylinder head removed in under 10 mins
Removing the head of a 4G63 in 10x speed. The project got delayed a few months. After finishing it and cranking it over, Interference in the cylinder was discovered. Shamefully, I admit my mistakes were: 1) Not putting the spark plugs in immediately after installing the head. 2) The bad habit of using my Valve Cover as a parts tray and 3) Putting off the project too long, so I didn't recognize a missing bolt from a custom fabrication. The head needed new valve seats, valves and some welding. Wiseco and the machinist both thought I'd be OK running the piston after smoothing out hot spots, but I ordered a new piston not wanting to risk the deep gouge in it with the high Boost I plan to run. Peace of mind is priceless. The danger in being over confident is sometimes you skip triple checking stuff. I've built that engine at least 5 times and got careless. You can see the port work I did on the head @ http://www.southernutahautos.com under "Tech Tips" and "Beyond Bolt-ons"





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 Dragster - First Track Day
Atco Raceway - 4/18/09 First day at the track with our 4G63 Dragster project. The converter is too tight to build Boost on the line at the moment but we're working on it!





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





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.





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.





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..





Mitsubishi Eclipse History 1990-2012
HISTÓRIA Mitsubishi Eclipse 1990-2012: 1990 Mitsubishi Eclipse GS turbo 2.0 16v 192 hp 280 Nm 1990 Mitsubishi Eclipse 1990 Plymouth Laser 1990 Plymouth Laser & Tina Turner 1990 Eagle Talon TSi AWD 1991 Mitsubishi Eclipse @ 2009 12 Rounds 1991 Mitsubishi Eclipse & 3000 GT 1991 Mitsubishi Eclipse 1992 Mitsubishi Eclipse GS turbo 2.0 16v 190 hp 280 Nm 1992 Eagle Talon TSi 2.0 turbo 195 hp 1992 Mitsubishi Eclipse 2.0 16v 192 hp 1992 Mitsubishi Eclipse & 3000 GT 1993 Mitsubishi Eclipse GS turbo 1994 Mitsubishi Eclipse 1994 Mitsubishi Eclipse GS-T 2.0 207 hp 290 Nm 1994 Mitsubishi Eclipse GSX turbo AWD 1995 Eagle Talon TSi AWD 1995 Mitsubishi Eclipse 1995 Mitsubishi Eclipse GST @ 2001 The Fast and The Furious 1995 Mitsubishi Eclipse GST mini by ERTL from 2001 The Fast and The Furious 1995 Mitsubishi Eclipse GSX 1995 Mitsubishi Eclipse 1996 Eagle Talon ESi 2.0 141 hp 1996 Mitsubishi Eclipse Convertible 1996 Mitsubishi Eclipse GSX 1996 Mitsubishi Eclipse 1997 Mitsubishi Eclipse @ 2008-2009 Knight Rider 1997 Mitsubishi Eclipse GST 1997 Mitsubishi Eclipse GST Spyder 1997 Mitsubishi Eclipse GSX 1997 Mitsubishi Eclipse 1998 Mitsubishi Eclipse SST Concept on 20" Aut4 2.0 turbo 2000 Mitsubishi Eclipse GT V6 2000 Mitsubishi Eclipse EV Electric Vehicle Concept 135 hp 250 Nm 2000 Mitsubishi Eclipse GT V6 on 17" 3.0 207 hp 280 Nm 2000 Mitsubishi Eclipse mini by Jada 2002 Mitsubishi Eclipse 2003 Mitsubishi Eclipse Spyder @ 2 Fast 2 Furious 2003 Mitsubishi Eclipse GS 2004 Mitsubishi Eclipse AWD Concept E 3.8 Hybrid V6 273 hp+Electric 202 hp 2004 Mitsubishi Eclipse Spyder mini by ERTL 2005 Mitsubishi Eclipse GT V6 2005 Mitsubishi Eclipse Ralliart Concept on 20" 2.0 turbo 400 hp 2005 Mitsubishi Eclipse Spyder 2006 Mitsubishi Eclipse GT V6 2006 Mitsubishi Eclipse mini by Norev 2007 Mitsubishi Eclipse GT V6 2007 Mitsubishi Eclipse Spyder 2008 Mitsubishi Eclipse GT V6 on 18" 3.8 266 hp 360 Nm 2010 Mitsubishi Eclipse 2010 Mitsubishi Eclipse Spyder GT 2011 Mitsubishi Eclipse GS Sport 2011 Mitsubishi Eclipse GS 2012 Mitsubishi Eclipse SE 2015 All New Mitsubishi Eclipse R Concept by Steel Drake Find us on https://www.facebook.com/pages/Carwp/505636076134244 DOWNLOAD IMAGES: http://CARWP.com.br Royalty Free Music by http://audiomicro.com/royalty-free-music Sound Effects by http://audiomicro.com/sound-effects





4g63 Mirage- Start up
Idle is at 1k =)





Piston Wiggle in my DSM
So im going to guess that whoever put this engine together had no idea what they were doing. All four pistons have a wiggle to them. You can almost tell in the videos that the gap is too big. Almost as if they were the wrong bore or something. Oh well, out with the old and in with a fresh 6 bolt.





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