Building up the engine

[Gizmo63T]

Hi everyone.

I hope you don't mind me opening my thread. I have been searching the forum and really found out useful stuff.
Here in Croatia we only have few of 4G63T engines so only way to get parts is from US.

Ok, so first for introduction of my car:
I drive FWD '90 Mitsubishi Colt GTi with SUPERTOP. Original engine was 4G61 but we manage to find 4G63T and swapped it.

When i got it, the car looked like this.

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Current state.

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When we swapped the engines only thing I had by then was Fidanza flywheel, OBX power pulley, Exedy stage 1 clutch kit, 2.8" exhaust and we pooled out balance shafts.
Rest of it was stock with SMIC from eclipse. The engine bay looks like this.

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Went to the dyno and it showed 217bhp. Now it is time to go a step forward.
Few days ago i found another crack on exhaust manifold.
First crack was welded by previous owner.

Oh yes, my goal is to have a quick street car, around 350 - 400 (I know even this HP is much because i don't have AWD, so no need to go above that). We don't have drag strips here so no need for drag car.
So here is the list of stuff that i had in mind.
Would like to go with
68HTA turbocharger
FP race manifold
GSC S1 power-division camshafts
Forged Wiseco pistons and Eagle rods
Evo 3 O2 housing
Skunk2 cam gears
FP GSS342 Fuel Pump
GM maf with FMIC and pipes
Cometic head gasket
ARP head studs
AFPR

Only thing i didn't decide is size of injectors and BOV.
I already bought EPROM ECU and ECMlink V3.
So I would like to hear your thinking and suggestions.
Have in mind that we don't have yards with wrecked 1G and 2Gs.
All the parts i can get is through ebay and this forum.
Have a really good friend over at 4g61t.org who helps me find stuff i need.
That is that.. I really appreciate your help. T
Thank you.

 

[BogusSVO]

With the Cometic Head Gasket, Both the block and head will need to be surfaced perfect
http://www.dsmtuners.com/forums/new...face-4g63t-cylinder-head-mls-head-gasket.html

http://www.dsmtuners.com/forums/cyl...0613-why-not-let-your-head-belt-surfaced.html

So you may want to consider using a composite like the mitsu organic or the felpro

As far as the build of the rest of the engine, looks decent.
You may want to reserch camshaft selction some more and add balancing the rotating assembly.

 

[Gizmo63T]

add balancing the rotating assembly

What is that?
I heard good things about S1 cams, especially that I don't need power above 7500 rpm.
And one question about S1, do they have magnetic pickup?

Big thanks on info for head gasket, that will help me alot.
Just need suggestion for injectors. How much would be good to have? 650, 750 or 850?

 

[BogusSVO]

Balancing the rotating the assembly..

Well the end result is a smoother running engine

All the pistons will be the same weight with in .5g
The rods get balanced, twice, once on the wrist pin end, then the overall weight is matched
Then the crank is spun up and brought into a zero balance. Some shops will want the Harmonic balancer, the Flywheel and the pressure plate, so all that can be zero'ed out.

Here is a test you can do

Grab 2 buckets, fill one bucket with 5lbs (2KG), next ftill the other bucket with 2lbs (1KG)
with a bucket in each hand, spin around in circles as fast as you can.
You will notice the 5lb (2KG) bucket wants to pull you off center

That is what happens to your crank when the weights are not matched up
It can and will cause bearing wear, shaking of the engine

I just weight matched a set of V8 pistons, factory sealed box, 6 of the pistons were in the 612.xg range, 1 piston was 610.xg and the last one was 615.xg
After balancing the pistons, they all weigh 610.X grams

 

[GofaST4life]

Looks like a great build!

One thing I would do though. - Relocate your battery to the trunk and make that intake flow much nicer.

Just my .02

 

[Gizmo63T]

Wow thanks BogusSVO. I hope I will find some one who can do that.
But those are great infos. I appreciate that.

@GofaST4life - Yes, I think I will have to do that.
Pipes for the intake (IC pipes) will be 2.5".

 

[Calan]

I just weight matched a set of V8 pistons, factory sealed box, 6 of the pistons were in the 612.xg range, 1 piston was 610.xg and the last one was 615.xg
After balancing the pistons, they all weigh 610.X grams

5g difference across a boxed set? That seems excessive (or maybe not these days).

Out of curiosity, what brand were they?

Only thing i didn't decide is size of injectors and BOV.

Since you will have ECMLink, you can go as big as you want on the injectors. (Some of them can still be a bit finicky and difficult to dial in though). For your goals, a good set of FICs somewhere in the 950-1150 range should work nicely depending on what fuel you plan on running... but you could always go bigger if there is a possibility of more power later (and there ALWAYS is .

For a BOV on a budget, I would recommend a good ole' cheap factory 1G. Crush it or garage mod it, and it will handle 30psi and 400hp all day long.

You may also want to consider going with a speed density (SD) setup rather than the GM MAF, since you'll have ECMLink and about everything you would need.

 

[BogusSVO]

Calan.. just a box of cheap cast pistons for a stock rebuild on a 350 SBC

But it is not uncommon to be 3g from lighest to heaviest, even in a high dollar set of forged.

 

[Calan]

Oh ok. I could see that on a set of cast replacements, but I figured a good set of forged slugs would be within a couple of grams at most.

Learn something new every day!

 

[Gizmo63T]

Since you will have ECMLink, you can go as big as you want on the injectors. (Some of them can still be a bit finicky and difficult to dial in though). For your goals, a good set of FICs somewhere in the 950-1150 range should work nicely depending on what fuel you plan on running... but you could always go bigger if there is a possibility of more power later (and there ALWAYS is .

Haha, that is true, but then I will have to bring one AWD Colt from US.
I will be runing pump gas "100" octan fuel. That is the strongest you can get here but it is not 100 as it says, but more like 95-96 oct.

You may also want to consider going with a speed density (SD) setup rather than the GM MAF, since you'll have ECMLink and about everything you would need.

I'm very unfamiliar with SD. I tryed searching topics about it and i found that people recomend SD over GM maf. As i manage to understand I need some kind of two sensors? But I still don't have a picture in my head.. is it a piece of hardware? Like MAF sensor? Would like to go on it but no one ever heard about it here at my place

 

[Calan]

I'm very unfamiliar with SD. I tryed searching topics about it and i found that people recomend SD over GM maf. As i manage to understand I need some kind of two sensors? But I still don't have a picture in my head.. is it a piece of hardware? Like MAF sensor? Would like to go on it but no one ever heard about it here at my place

In a nut shell, the ECU can use

1. a MAF to "measure" airflow into the engine (stock or GM MAF setup), or

2. an IAT (intake air temperature) sensor and a MAP (manifold absolute pressure) sensor to calculate how much air is entering the engine. This would be SD.

The end result is the same....the difference is in the way the ECU determines how much air it has to deal with. There are a few differences in how you calibrate things in ECMLink, but the concepts are the same. Since it's a good idea to log boost anyway (MAP sensor), I consider the IAT to be the only additional requirement for SD...and of course you no longer need a MAF.

Here is an intro to SD on the ECMLink wiki: http://www.ecmtuning.com/wiki/sd101

 

[Gizmo63T]

Great thank you.
Definitely gonna go with SD setup then.
I found on ebay IAT and a MAP sensor, so that is all I need?
Cool, just need to study everything on ecmlink page about it

 

[TSiAWDRatlemstr]

Your car is sweet! I just installed some stock EVOVIII injectors in my car and am happy with them. They support 300-400hp on an Evolution, so I can't imagine they wouldn't do the same on an old 4G63. Plus, they are easy to dial in and you don't loose idle quality. I had FIC 1050s and they were a lot more than I needed. Good call on the speed density. That will be a nice setup.

 

[Calan]

Cool, just need to study everything on ecmlink page about it

Sounds like you are being methodical and going about this in the right way. That is a refreshing change considering the way the majority of people go about things these days.

 

[Gizmo63T]

Thank you TSiAWDRatlemstr! Definitely gonna check up more about injectors. Because I have to order them from US and I don't want to order twice

@Calan - hehe I really like my car, and I can't afford to put something on the engine that will damage it or make some problems, because this is the only engine I got.
I can't go to junkyard and buy another one
I feel like Mad Max.. The last of the V8!

 

[Lofty]

I like this guy, he's alright.

I've swapped one of these before, fun cars.

 

[skatershawn]

Nice Colt... REALLY Want one! :/

 

[Gizmo63T]

Have one question..
The weather here is much colder and in last couple a days noticed my boost is going a bit high..
Does that have anything to do with cold air? Or something is wrong? Like it is over boosting..
The normal pressure is up to 5500rpm. after that it goes up.

Here is a clip:
MOV00722.mp4 video by Blek_Stena - Photobucket

It is in 3rd and 4th gear.
Sotck boost is around 0.7-0.8bar. Now it goes up to almost 1.4..
Ina psi it is:
0.8bar is cca 11psi, and 1.4bar is 20psi.

Everything is stock except 2.8" exhaust.

And I do feel a bit stronger acceleration above 5500rpm.. Like it is Vtec
Not much but a little..

Is it the wastegate? Or the gauge is showing wrong.. It is an electric one

 

[FlashBack-Cro]

Buy another gauge