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)
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
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
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.
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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Hyundai Elantra 4g63 Shortblock Assembly
HOLD ON TIGHT! HERE WE GO!
We begin the blueprint and assembly on my 1992 Hyundai Elantra's
bastardized 4g63. The parts used in this are from a mash of different
brands and models outside of the typical 2.0L 4g63, but the specs and
standards I am following for its assembly are for the 2.0L DOHC.
If you want to follow along in your service manual to verify what I've done
here in this video, the processes we cover here detail pages 11C-95 through
11C-105 of the 1g Overhaul manual. I would prefer you not rip them from
the binding and throw them away, relying only on this video for
instruction... but rather use this video as a motivational guide, and as a
demonstration of the techniques involved in those sections.
You gotta do the cooking by the book.
I never had any intention of making instructional videos on this particular
car, but after it blew up I slowly realized it's actually a better case
study for how a 4g63 ticks than anything else in my driveway. There are
several reasons for this. One being that it's a mix of parts that
shouldn't be bolted together, and the other is that many of you watching my
videos aren't trying to build a 600hp engine out of aftermarket parts.
You're trying to put back together what used to be your daily driver. This
car covers those bases. Don't think for a second I won't go through this
same trouble and level of detail for the GSX. I will. When I do, having
this information in this video will give you a better understanding on how
and why I do things the way I do when I get there.
This was the shortest I could condense this video. I've never uploaded a
video this long, and I hope I never have to do it again. It took a month
to create on cutting-edge equipment, 16 hours to export, and 9 hours for
YouTube to process. My script for the voiceover is 6 times longer than the
whole script for the movie Pootie Tang. 6 times. Longer. Than a
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.
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. :)
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
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
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.
mitsubishi engine rebuild part 2
yep its getting shape a lol figers crossed if the fave are still opens e
corect i have no idea how it shoot opens richt on an 4 cil xd
My Galant and the process of rebuilding its engine