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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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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 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.





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"





1991 GSX rebuild
Rebuilding my 4g63t dsm





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.





HOW AN ENGINE IS BUILT
THIS IS HOW AN ENGINE IS ASSEMBLED





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!





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.





4G63 Lifter installation without special tool part 2
In this segment I reinstall the rockers over the new lifters. Again, no special tools, or removal of the timing belt, cams, or cam caps. All we are doing here is putting the rockers back in place over fully bled aftermarket (topline) "3g" big hole lifters. These are NOT ebay lifters. I can't speak for them - I have never used them. *** Some side notes and related info*** -This car was purchased used with about 22k on it. They started ticking heavily about the third day after I bought it 2 years ago... and have ticked for about 20k more miles. -I recently switched from a 969400011 rom (05 rom) to a patched version of 96530006. Which must run different knock filters, as I had excessive part throttle knock I previously did not have. -Topline lifters stopped the part throttle knock -While they were pumping up and chattering, I couldn't even drive the car. I got repeated high knock counts to the point I could feel timing being pulled through the floor. -Once they filled up with oil and went silent I have NO knock. Even between gears, from stops, after a aggressive throttle then reapplication of throttle... Basically all the places I had knock before, I don't now. Which is great when it's this simple. Yay for lifters that don't tick.





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





Danny's 4G63 Engine Build Part 2
More progress has been made.





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..





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. :)





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