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)
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
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.
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.
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
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.
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
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
Cylinder Block Machining Video - Engine Building DVD
Buy the "Basic Engine Building" DVD
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
Get the full DVD with all of the interactive menus, Tools section and
engine Glossary terms here...
Educating the Automotive Enthusiast!
Don't forget our Holley Installation & Tuning DVD. Sample clips on our
youtube page and at our store here...
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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..