1G Engine Teardown and Inspection

[thejollyrancher]

Hi Everyone,

I recently picked up a supposedly built 6 bolt 4G63 from a parts car. The fact that it was being parted out has me a little sketched out but I got it pretty cheap. Im looking to tear it down and see what condition everything is in. Anyone have a link to and specs that the engine should fall between? What should I look for? Anything I should keep in mind while reassembling? Any tips would be nice, this is the first time I'm gonna be taking an engine apart.

Thanks!

 

[xlevanx]

Go buy yourself a Haynes or chiltons manual. Has all the torque specs, clearances, ect. As what to look for scratches in the bore, check block and head for warpage with a straight edge. Pretty much your goin that far bring it to the machine shop to get checked out honed crank polished, definitly get new rings and bearings. No sense to take it all apart to not change those things.

And when it comes to reassembly be clean. The cleaner the better any dirt and grime will ruin a new motor. Good luck! It's scary for the first time but you won't regret it. It's a great learning experience.

 

[thejollyrancher]

I have haynes but i didnt realize it had clearances in it. Ill give that a look. Thanks!

 

[laserspeeddemon]

Some of this is going to require a machine shop to do. For example measuring the piston to wall clearance, main bearing clearance/roundness, rod bearing clearance/roundess, etc.

 

[GST with PSI]

Some of this is going to require a machine shop to do. For example measuring the piston to wall clearance, main bearing clearance/roundness, rod bearing clearance/roundess, etc.

These are all measurements you can do yourself with the proper tools. Those tools aren't in in your typical tool box, though. In addition, most people who aren't familiar with the process would have a machine take care of it. The problem there is, you're relying on a machine shop to do things right. Most reputable machine shops will get the job done right the first time, but you'll never have that piece of mind you get after doing the job yourself.

Engine building and blueprinting isn't difficult, it's just time consuming and requires great attention to detail. And, as I mentioned, it requires some specialty tools. Micrometers, T-gauges, V blocks, and a good dial indicator are a good start. I picked up a bunch of used stuff from a machinist who was getting out of the business. Look around for deals, and you'd be surprised what you can find.

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Need the specs? Here ---> http://www.galantvr4.org/docs/1g-90-92-4g63overhaul.pdf

Need to check bearing clearances? Measure with T-gauges/micrometers and double check with Plastigage.

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Main caps

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2 pistons in, checking the rod cap oil clearance.

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You can even do some of your own balancing. Of course, you aren't balancing an entire rotating assembly without some serious machinery, but for a basic backyard build, there's not much that you can't do yourself.

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[92AWDHX40]

If you cant do it any machine shop can, do it and rest assured youll be good.

 

[laserspeeddemon]

These are all measurements you can do yourself with the proper tools. Those tools aren't in in your typical tool box, though. In addition, most people who aren't familiar with the process would have a machine take care of it. The problem there is, you're relying on a machine shop to do things right. Most reputable machine shops will get the job done right the first time, but you'll never have that piece of mind you get after doing the job yourself.

Engine building and blueprinting isn't difficult, it's just time consuming and requires great attention to detail. And, as I mentioned, it requires some specialty tools. Micrometers, T-gauges, V blocks, and a good dial indicator are a good start. I picked up a bunch of used stuff from a machinist who was getting out of the business. Look around for deals, and you'd be surprised what you can find.

You must be logged in to view this image or video.

Need the specs? Here ---> http://www.galantvr4.org/docs/1g-90-92-4g63overhaul.pdf

Need to check bearing clearances? Measure with T-gauges/micrometers and double check with Plastigage.

Main caps

2 pistons in, checking the rod cap oil clearance.
\

You can even do some of your own balancing. Of course, you aren't balancing an entire rotating assembly without some serious machinery, but for a basic backyard build, there's not much that you can't do yourself

This can be VASTLY misleading. This is not a task that your everyday home garage wrench tuner can perform. There is a HUGE difference between having the tools and having the knowledge and experience to accurately use them. This is not something that is small. If you are going to do it by yourself for the first time, I HIGHLY suggest that you do it within someone who have had experience at least building several motors; but it would be ideal to have an experienced machinist with you at the time you attempt it.

To say having the tools means you can perform the build, with all it's incredible tolerances and clearances, is like saying handing a M82 Sniper Rifle to some random Joe makes them an expert marksmen. Even the highly trained infantryman, has trouble shooting a Sniper Rifle at first. But with expert instructors, training and practice, they get the hang of things.

 

[jbeaton9292]

yes this can be a scary thing but if you do lots of reading and looking at things and calling and or going to shops and asking questions you should be able to get it done without much trouble like stated above just be clean about everything and you will be very proud when it is finished

 

[GST with PSI]

This can be VASTLY misleading. This is not a task that your everyday home garage wrench tuner can perform. There is a HUGE difference between having the tools and having the knowledge and experience to accurately use them. This is not something that is small. If you are going to do it by yourself for the first time, I HIGHLY suggest that you do it within someone who have had experience at least building several motors; but it would be ideal to have an experienced machinist with you at the time you attempt it.

To say having the tools means you can perform the build, with all it's incredible tolerances and clearances, is like saying handing a M82 Sniper Rifle to some random Joe makes them an expert marksmen. Even the highly trained infantryman, has trouble shooting a Sniper Rifle at first. But with expert instructors, training and practice, they get the hang of things.

Most average wrench turners should be able to handle the task without issue. Anyone who can't read a micrometer and do a little simple math has no business working on a car in the first place. However, if you can handle the aforementioned tasks, you'll do just fine building an engine. There is enough information available to the common joe to build a 4G63 from the ground up. If you let this kind of thing intimidate you, then you're probably going to screw it up. But, if you take your time and pay close attention to detail, building a motor is pretty straight forward.

Marksmanship and engine building are like comparing apples to oranges, as there's almost no correlation between the two. In marksmanship there are debates on the best shooting position, grip, breathing techniques, ammunition, etc. With engine building, it's in spec, or it's not. Pretty straight forward when comparing the two disciplines. Of course, whether you're shooting or building an engine, it always helps to have a knowledgeable helping hand to give some guidance along the way. For people who don't have that available to them however, taking the task on yourself would be perfectly acceptable IMO. When you have to rely on yourself to get shit right, (or else suffer the consequences) you tend to learn a lot in a very short timeframe.

 

[92AWDHX40]

Just make sure you check everything over and over again, I built a engine a long time ago, it takes time but hey It worked until I sold it had a few issues but that was on my non turbo.

 

[AllanL]

this one as well: http://www.dsmtuners.com/threads/bogussvo-how-to-links-and-other-info.450429/

 

[BoostedBeaver]

If you do decide to go through the motor, here is a thread where I documented my build. Hopefully some of the post will help you out.

http://www.dsmtuners.com/threads/1990-eagle-talon-sleeper.427853/

 

[thejollyrancher]

this one as well: http://www.dsmtuners.com/threads/bogussvo-how-to-links-and-other-info.450429/

If you do decide to go through the motor, here is a thread where I documented my build. Hopefully some of the post will help you out.

http://www.dsmtuners.com/threads/1990-eagle-talon-sleeper.427853/

Thanks guys! Ill for sure be looking over these. Ill update this thread with any issues or anything if I run into them.

 

[laserspeeddemon]

Most average wrench turners should be able to handle the task without issue. Anyone who can't read a micrometer and do a little simple math has no business working on a car in the first place. However, if you can handle the aforementioned tasks, you'll do just fine building an engine. There is enough information available to the common joe to build a 4G63 from the ground up. If you let this kind of thing intimidate you, then you're probably going to screw it up. But, if you take your time and pay close attention to detail, building a motor is pretty straight forward.

Marksmanship and engine building are like comparing apples to oranges, as there's almost no correlation between the two. In marksmanship there are debates on the best shooting position, grip, breathing techniques, ammunition, etc. With engine building, it's in spec, or it's not. Pretty straight forward when comparing the two disciplines. Of course, whether you're shooting or building an engine, it always helps to have a knowledgeable helping hand to give some guidance along the way. For people who don't have that available to them however, taking the task on yourself would be perfectly acceptable IMO. When you have to rely on yourself to get sh** right, (or else suffer the consequences) you tend to learn a lot in a very short timeframe.

Most dealerships don't build motors they just trade in a crate motor. So by your example all the mechanics at my local Ford shouldn't be working on cars. It's not about how to READ a micrometer, its learning to feel the drag properly. There are HUNDREDS of examples of RACE SHOPS screwing up engine builds. The last motor I built had rod knock within 5 miles, not because I did anything wrong, but because ONE journal on the crank tapered at of spec by maybe 0.005". It also is very pointless to buy these high end tool sets to use them ONE time. If you want to learn, great! Just know that there is a chance you'll mess it up. Don't (be like me, and) let this car be your only way to work. If you are going to do mechanic work on the side (like I do) GREAT! But if you get it wrong there are consequences. I would just caution you (GST with PSI) not to downplay the experience and knowledge it takes for people like JAM to build good motors.

And ALL metaphors are oranges to apples that is why they are metaphors.

 

[donniekak]

If a crank journal has .005" taper, you don't even need real tools to find out. Plastigauge would show that bad of an issue.

 

[GST with PSI]

Most dealerships don't build motors they just trade in a crate motor. So by your example all the mechanics at my local Ford shouldn't be working on cars. It's not about how to READ a micrometer, its learning to feel the drag properly. There are HUNDREDS of examples of RACE SHOPS screwing up engine builds. The last motor I built had rod knock within 5 miles, not because I did anything wrong, but because ONE journal on the crank tapered at of spec by maybe 0.005". It also is very pointless to buy these high end tool sets to use them ONE time. If you want to learn, great! Just know that there is a chance you'll mess it up. Don't (be like me, and) let this car be your only way to work. If you are going to do mechanic work on the side (like I do) GREAT! But if you get it wrong there are consequences. I would just caution you (GST with PSI) not to downplay the experience and knowledge it takes for people like JAM to build good motors.

And ALL metaphors are oranges to apples that is why they are metaphors.

Dealerships install crate motors because it's the least time and labor intensive process. I'd be willing to bet even your entry level Ford tech could throw a motor together without much trouble.

Doing one thing wrong is sometimes all it takes. In your case, that something was not blueprinting the crankshaft properly. It happens to the best of us, and that's how you learn, albeit an expensive lesson. You shouldn't let that intimidate you, or discourage you from trying again. It doesn't matter if you're an average Joe, or some high end race shop; like I said, putting a motor together is just nuts, bolts, and great attention to detail. There are enough resources out there to guide even those who have zero experience turning wrenches, and those who feel that's not enough can always reach out to members of communities like this one.

If you are rebuilding the motor for your only means of transportation, what I'm saying probably isn't something you should undertake. When things like getting to work may be hindered by your mistakes, you might want to leave it to a professional. Also, when you're in a rush to throw things back together, things get missed. If you're looking to learn, doing it on your DD probably isn't a great idea.

As far as buying tools, I look at it as in investment. Even if I don't use them everyday, I have them when I need them. If you build 3 or 4 motors in your lifetime, they end up paying for themselves. You can find good deals on used stuff as well, so I don't recommend blowing your load on a bunch of mics and such.

Lastly, there's a big difference between doing quality machine work, and doing basic blueprinting and assembly. I'm speaking solely about the latter. When there are HUNDREDS of examples of RACE SHOPS screwing up engine builds, that's all the more reason to get savvy and be able to double check their work on your own.

 

[laserspeeddemon]

I 100% agree with your last statement/paragraph. The reason my last engine went in my car was because I trusted a shop and had 5 days before I shipped out to Afghanistan, I rushed it.

That was extremely foolish of me.

 

[briansmith]

Engine building is not difficult. Ur not building anything. Ur assembling!!!!!! Lol. Read the specs. Do the math I kno it's been a long time since people have been in school if u don't understand something. Read I'm again as for speed shops screwing things up. U can't rly expect someone to kno everything about ur engine if they Dont specialize in it. What applies to a 350 small block may not to a 4g63t. It's ur responsibility to provide the specs to a shop. After all it is ur engine I have assembled many engines and never had any problems because I followed the steps. If a part is not in spec toss it replace it or machine it to spec if able. If ur unsure take it to a shop with the specs in hand and have it checked don't rush it take ur time do it right check double check then triple check key to a great engine is not the parts used it's attention to details people to tell horror story's of how there fresh build messed up didn't follow the steps. And can blame it no one but their self. U are finally quality control of a build

 

[laserspeeddemon]

Funny, you say that. I started out building old schoo V8s with my dad.

 

[briansmith]

Hahaha. Hey it happens to the best of use. Not calling anyone out or showing disrespect to anyone. I've broke plenty in my time from lack of knowledge. And we all start somewhere. Learning is part of the fun. It's costly but fun. If it wasn't No one would do it. Our cars get a bad wrap as being Unreliable or fickle. And that not the case it's usually abused or improperly modded and assembled just learn something from it so the mistakes u make today don't happen tomorrow.

 

[laserspeeddemon]

Our cars get a bad wrap as being Unreliable or fickle. And that not the case it's usually abused or improperly modded and assembled just learn something from it so the mistakes u make today don't happen tomorrow.

Another thing I agree with. I've made my share of mistakes.... if you can't tell from my join date.

 

[briansmith]

Haha. Me too. I've broke lots of dsm stuff. Hahaha