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How to Have a 4G63 head rebuilt.

Posted by BogusSVO, Nov 20, 2011

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  1. BogusSVO

    BogusSVO Proven Member

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    What Happens to a head in a machine shop

    First Not all shops have the same equipment and the procedures from one shop to the next can and will differ.
    Some shops cater to domestics and others imports or even diesels.
    Some shops will view everything as a "stock" rebuilds.
    So....
    The most important thing to know is the shop you use and the equipment they will use.

    The subject head is a Mitsubishi 4G63 7 Bolt

    The first thing that should happen is the machinist looks at the head. Checking for the obvious damage, broken bolts, stripped bolt holes, bent valves, ect.
    Picture001.jpg

    At this point it is up to you as the customer, inform the shop what you want done, such as...
    1) Pressure test for cracks
    2) Valve job
    3) Surface
    4) Guide work
    5) Any performance work wanted
    Also now is the time to speak about who will provide what parts, valves, seals, guides, springs, ect.

    Now the shop should be able to give you, the customer, an approximate estimate of what the parts and labor will cost.

    You as the customer have the choice to agree, or go somewhere else.
    Now that your head is at the machine shop, and you have agreed to have the work done.

    The first thing to happen is the head will be disassembled.

    The tools needed are
    027.jpg

    Wire basket for small parts springs, valves, ect
    Small container for valve locks
    Valve lock release tool (socket method)
    Hammer
    10mm socket
    12mm socket
    12mm socket
    Ratchet
    5.5mm allen bit socket or wrench
    Pocket magnet
    Long reach needle nose pliers w/45* bend
    Impact gun (not pictured)

    Cam gears come off first, use impact with the 17mm socket
    DSCF5436.jpg

    Next remove the cam tower caps, use impact or ratchet w/12mm socket.
    Start at the ends working towards the center
    003.jpg


    004.jpg

    Once the cam caps are removed, lift the cams out.

    005.jpg

    Next lift the roller followers out
    006.jpg

    Now you can remove the HLA's
    008.jpg
    007.jpg
    Now remove the oil spliter
    011.jpg


    Now remove any other small bolts
    009.jpg

    This is a "heat tab" Most machine shops use them.
    The center will slide down at 240-250* and totally dissolve at 260*
    010.jpg

    Next is to remove the valve train.
    Yes the same method that a lot of DIY people use are used in a machine shop.
    Use a basket and a paint cap, have a pocket magnet handy too.
    029.jpg
    Have your "tool" and hammer ready to go
    Place the tool on the spring retainer and give it a firm whack.
    The locks will stay in the tool and release the retainer and spring.
    Place the retainers and spring in the basket
    031.jpg
    Fish the valve locks out of the head casting with the pocket magnet.
    032.jpg
    Place the valve locks in the paint can cap.
    033.jpg
    Now remove the spring seats with the pocket magnet and place in the spring basket to be cleaned.
    034.jpg
     
    Last edited by a moderator: Jun 5, 2014
  2. BogusSVO

    BogusSVO Proven Member

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    Next roll the head over and remove the valves and place in the basket.
    035.jpg
    This head was rebuilt once before, it must have had bent valves.So I will change the valve guides.
    Now roll the head back over and remove the valve stem seals, throw these in the trash.
    037.jpg

    Next grab the 5mm allen bit and remove all the oil galley plugs. Keep these to be installed later, place in the paint cap with the valve locks.
    038.jpg
    The last thing done is to remove the cracked valve guides.
    041.jpg

    Now that the head is fully stripped, it can be tech'ed
    First thing is to do a quick clean on the head gasket surface.
    017.jpg
    Next is to measure head thickness.
    021.jpg
    Now to check to see how bad the head is warped.
    DSCF3975.jpg
    Notes are taken to reference back too.
    025.jpg
    If it all checks out, it goes to cleaning.
    It gets thermal cleaning, then glass beaded.
    042.jpg
    Next oil port mod #1 is done
    065.jpg
    Next all the oil galleys get gun brushed
    049.jpg
    Now the entire head will be blown off with compressed air, including every bolt hole to make sure there is no glass bead media is left in or on the casting.
    047.jpg
    next is a coat of spray paint to seal the casting.
    051.jpg
    Now new guides can be installed.
    DSCF3932.jpg
    They are set to height.
    DSCF3934.jpg
    Now the valve seats can be cut.
    Fist is to set the head in the machine and secure it properly.
    DSCF4001.jpg
    The proper sized pilot is selected.
    DSCF4003.jpg
    The head is now leveled in the machine.
    DSCF4004.jpg
    Now to set up the seat cutter.
    First is to find where the seat is to make contact on the valve.
    DSCF4005.jpg
     
    Last edited by a moderator: Jun 5, 2014
  3. BogusSVO

    BogusSVO Proven Member

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    Now the cutter bit can be set.
    DSCF3899.jpg
    The seats are cut.
    046.jpg
    Now the valves are lapped.
    043.jpg
    The small parts of he head have been cleaned, retainers, springs ect.
    DSCF5528.jpg
    Valve springs are tested.
    DSCF5526.jpg
    Most valve springs have been found weak, so New BC1100 springs will be installed
    (stock spring on left, BC spring on right)
    DSCF5524.jpg

    A broken exhaust stud was found and removed.
    DSCF5554.jpg

    The valves are ground.
    DSCF5519.jpg
    Ground and ready to be installed.
    DSCF5520.jpg

    Now the head can be surfaced.
    The head is set up and secured to the milling machine.
    066-1.jpg
    The proper surface finish is milled for the head gasket to be used.
    (a composite for this one) You can see that this head was belt surfaced before.
    068-1.jpg
    The head is now blown out to remove metal flake from milling and seat cutting.
     
    Last edited: Sep 18, 2013
  4. BogusSVO

    BogusSVO Proven Member

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    Now that the machining is done, it is time to assemble the head.

    Valve tip height is checked to make sure it is in spec.
    DSCF5531.jpg
    The valves are removed, lubed up and slid back into the same hole they came from.
    DSCF5527.jpg
    A package of valve seals found in a head gasket set.
    DSCF5534.jpg
    Now the seals are pushed on by hand
    DSCF5528.jpg
    Now seals can be installed, this is my "hi-Tech" seal installer.
    DSCF5536.jpg
    Now the seals are tapped into place securely.
    DSCF5537.jpg
    Now spring shims are installed if needed.
    DSCF5529.jpg
    The spring shim goes on before the spring seat.
    DSCF5530.jpg
    Now the cleaned spring seats are installed.
    DSCF5532.jpg
    On top of the spring shims.
    DSCF5533.jpg
    The new valve springs, BC1100
    DSCF5538.jpg
    Now the new BC1100 springs are placed in the head, on the spring seat.
    DSCF5539.jpg
    I will set the head back in the TnS 2000 Seat and guide machine, Using this adapter I will compress the valve springs.
    DSCF5542.jpg
    Now before I compress the spring, I will take the valve spring retainer.
    DSCF5540.jpg
    Install the valve locks,
    DSCF5543.jpg
    Then place it on top of the spring.
    DSCF5541.jpg
    Now with the spring and retainer compressed,
    DSCF5544.jpg
    I can push the valve locks into place.
    DSCF5545.jpg
     
    Last edited by a moderator: Jun 5, 2014
  5. BogusSVO

    BogusSVO Proven Member

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    Repeat the process till all the springs and locks are seated properly.
    DSCF5546.jpg

    Now this customer is going to install new 3g HLA's. So no need for me to install the last of the valve train.
    I check the valve to seat seal one last time.
    DSCF5561.jpg
    I did install the cam tower caps on their proper side and position.
    Each cam tower bolt received a quick dip in oil, since all the bolt threads are dry.
    DSCF5555.jpg
    Now the oil galley plugs received a dab of sealant.
    DSCF5557.jpg
    Then started by hand to prevent cross threading.
    DSCF5558.jpg
    Then tighten to seal.
    DSCF5559.jpg

    I measure the head for thickness and make a not of how much was removed.
    DSCF5556.jpg

    The final step is to CC the combustion chamber so proper compression ratio can be calculated.
    DSCF5560.jpg

    This head is now done, and ready for the customer to pick up and install.
     
    Last edited by a moderator: Jun 5, 2014
    miliman13 likes this.
  6. BogusSVO

    BogusSVO Proven Member

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    Finally finished it!! :hellyeah:
     
  7. nitrouskris

    nitrouskris Proven Member

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    great post. can you pm your info I would like to sent some business your way. also what do you think about taping the egr port and pluging it from the head
     

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  8. BogusSVO

    BogusSVO Proven Member

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    I do not see why a somple 1/4 NPT plug would not work on blocking off the EGR port.
     
  9. broken_eclipse

    broken_eclipse Proven Member

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    Good write up, Pretty much the same way I rebuilt mine.
     

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  10. C_Keagy

    C_Keagy Supporting Member

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    Pretty good write up!

    Care to elaborate more on testing valve springs and checking CC of the combustion chambers?
     

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  11. Talondvr

    Talondvr Proven Member

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    Couple questions?? Where is the heat tab at and what's its purpose? Also curious about how to know if spring shims are needed.
    Thanks for all your input on tuners here. I've learned a lot from you. :)
     

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  12. C_Keagy

    C_Keagy Supporting Member

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    Wow not sure how I missed those. Thanks!!
     

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  13. skatershawn

    skatershawn Proven Member

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    Love it! Love the deducation you have to provide us with your extemely helpful writeups. Not sure ill ever tackle this myself but its great to really know how its done.
    A+
    110%
     
    Last edited by a moderator: Jul 10, 2014

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  14. bryanwheat

    bryanwheat DSM Wiseman

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    The heat tabs are there to tell if the head has been overheated.
     
  15. jjrock5

    jjrock5 Proven Member

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    Great post.
     
  16. BogusSVO

    BogusSVO Proven Member

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    This ^^^^ Machine shops and rebuuilders install them to know if the head has been overheated, and if the center part of the tab is melted or gone, it voids any warrenty you may have had.

    I have written a few over the couple years that I have been on this board.
    I doubt may have read all the ones I have posted.

    DSM Wiseman BigWoo wrote this, It is a great read!
    http://www.dsmtuners.com/forums/articles-engine-fuel/303225-engine-machine-work-explained.html

    http://www.dsmtuners.com/forums/newbie-forum/341028-4g63t-head-oil-port-mod.html

    http://www.dsmtuners.com/forums/cylinder-head-short-block/341885-oil-port-mod-2-4g63t.html

    http://www.dsmtuners.com/forums/newbie-forum/341209-4g63t-valve-spring-info.html

    http://www.dsmtuners.com/forums/newbie-forum/341287-how-test-valve-springs.html

    http://www.dsmtuners.com/forums/cyl...how-aluminum-head-pressure-tested-cracks.html

    http://www.dsmtuners.com/forums/articles-engine-fuel/341621-how-cc-combustion-chamber.html

    http://www.dsmtuners.com/forums/newbie-forum/341218-how-change-valve-guides-4g63t-head.html

    http://www.dsmtuners.com/forums/newbie-forum/341297-how-replace-seats-aluminum-head.html

    http://www.dsmtuners.com/forums/newbie-forum/341288-why-have-your-valves-back-cut.html

    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

    http://www.dsmtuners.com/forums/cylinder-head-short-block/413772-how-clean-head-gasket-surface.html

    http://www.dsmtuners.com/forums/articles-engine-fuel/341627-how-check-head-warp.html

    http://www.dsmtuners.com/forums/cyl...how-measure-4g63-cylinder-head-thickness.html

    http://www.dsmtuners.com/forums/articles-engine-fuel/341636-how-lap-valve.html

    http://www.dsmtuners.com/forums/newbie-forum/420313-how-fluid-test-4g63-cylinder-head.html

    http://www.dsmtuners.com/forums/cyl...heck-piston-deck-clearance.html#post152107571

    http://www.dsmtuners.com/forums/cyl...-deck-4g63-cast-iron-block.html#post152790451

    http://www.dsmtuners.com/forums/art...ss-fit-pistons-balace-rods-6bolt-1g-4g63.html


    http://www.dsmtuners.com/forums/newbie-forum/341295-how-distroy-head.html

    http://www.dsmtuners.com/forums/cylinder-head-short-block/362154-how-final-wash-engine-block.html

    http://www.dsmtuners.com/forums/cylinder-head-short-block/342138-how-fix-balance-hang-pistons.html

    http://www.dsmtuners.com/forums/newbie-forum/341291-how-flywheel-resurfaced.html

    http://www.dsmtuners.com/forums/newbie-forum/341293-how-lighten-stock-cast-iron-flywheel.html

    http://www.dsmtuners.com/forums/newbie-forum/420506-how-remove-broken-bolt.html

    http://www.dsmtuners.com/forums/articles-miscellaneous/361131-how-install-heil-coil.html

    http://www.dsmtuners.com/forums/new...le-fuel-pressure-regulator.html#post152724177

    Thanks to all that learn from my posts! I hope it helps when you go to yourl local machine shops to get your heads and blocks done!
     
  17. skatershawn

    skatershawn Proven Member

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    HAHA, a FEW??

    Good Sh*t man, thanks for being so helpful.
     

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  18. G-UNIT

    G-UNIT Proven Member

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    Awesome post!
     
  19. renovatdkitchen

    renovatdkitchen Proven Member

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    I love green Monster's
     

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  20. BogusSVO

    BogusSVO Proven Member

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    I live on those things!!!
     
  21. renovatdkitchen

    renovatdkitchen Proven Member

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    Same here. Got another job as well to get the Talon back on the road. 5 hours of sleep and hard labour. If I didn't know better, I'd say they're hard to quit. Survived a week without and that's it. They do make a great difference though.
     

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  22. BogusSVO

    BogusSVO Proven Member

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  23. RayBan GST

    RayBan GST Proven Member

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    5 stars is not enough for you for this great and lovely POST

    10000000000 stars at least thanks a lot for your help :thumb:
     

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  24. 97mitzugst

    97mitzugst Proven Member

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    Thanks for this thread! This will really come in handy when I actually start my engine build.
     

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