4g63 Evo Engine build - NLC

[philthy]

Always wanted to do a proper engine build from scratch and since I sold my 9 earlier in the year my intention was always to get another 5/6 RS.

So I thought in the meantime I would build an engine ready to 'plop' in if a good car comes up for sale.

Started off a few weeks back when I bought a 35k mile engine from a cat C evo 6, ran nice in nstandard form so was a good choice for a build.





Managed to get it from the back of my van onto the engine stand on my own...:blah:





Had some help with the stripdown.











Crank coming out - again with some help





The pistons out showed not a massive amount of wear on the bores but pretty glazed.





Keeping track of what goes where -





While I was waiting on parts coming I painted the rocker cover.








Had a deal with my fiance that she didnt mind me buying dress up parts for the engine as long as they were purple - she obviously doesnt know how much HKS stuff costs :mhihi:


Parts start to arrive- K1 rods attached to 85.5mm Wiseco pistons







Got the block machined by AGRA in dundee to suit pistons and also decked, that reminds me I need a bigger headgasket.





Torqued down crank to check bearing clearances which are good within tolerance. ACL bearings used all round, ARP studs/bolts.




Still waiting on piston rings and balance shaft eliminator kit to arrive but assembled the crank and checked the bearing clearances on the rods today.





Took out the balance shaft bearings and fitted a couple parts, the right way around though!





New parts arrived from Indigo-gt so will be fitting these tomorrow



Got a fair bit of the build back up done today, had about 4 hours to get stuck in.

Started off by fitting balance shaft eliminator into the oil pump, flipping the bearings 180 degrees - no pictures Im afraid.

Gapped the rings for each bore and fitted them to the pistons





Fitted the pistons








Torqued the rods bolts and measured the stretch, should have taken a picture of this.

Oil pickup etc fitted



Thought I might as well fit the head so the head studs on and cosworth 1.3mm headgasket in place



Head on and head bolts torqued down



Dummy fit of timing belt and rocker cover, new cams ordered so will need to wait for them and I can get the timing done.





Top service from DS Motorsport - delivered within 24 hrs.



Bit of an update for you all- got round to fitting the new rod bolts and the cams, checked the p/v clearance too.
Melted my brain measuring the timing with the dial gauges but got there in the end







Rocker cover on and it's ready for fitting the belt covers

A nice shot of the rocker cover colour and finish



Next update will be the new car this will bring going in.
will update this post with more pictures/details - enjoy :smthumbup

[gambler]

Thanks for posting that Phil. I enjoyed seeing how an evo engine goes together. Im used to things going in sideways! The 4g63 seems to be the choice of champions when it comes to evo engines. I know both cpr cars were 4g63.

What are your plans with the car? Track days, sprints, Time Attack? 500-550 in a 5-6 should make a great car.


Keep up the good work

[SAJ]

Nice work, keep the updates coming.

[Shug]

Great post.

[philthy]

Cheers guys, the plans are mainly to be used for track days and a few sprints I think, maybe even knockhill time attack at some point.

Taking my time over it, got a few parts on the shopping list before it can go any further.

[Mike Scib]

Look forward to the updates.

[Dominic]

Top effort

Keep the updates coming

[Scotty C]

Had a deal with my fiance that she didnt mind me buying dress up parts for the engine as long as they were purple

ye whatever

nice work, i hope king K is reading this

[Modena Scotland]

[philthy]

Small update added to first post. It looks pretty much done but still got a lot of work to do.
Thinking about porting inlet manifold in the meantime

[BigD]

Nice work, brings back memories. I loved the plastiguage, so simple but effective.

Wiseco's are what I used in my drop-in and never had any issues with them. Stock like even from cold.

What annoys me with Evos though is that the engine build can be the easy and cheapest part. It's the ECU, fueling, injectors, turbo, manifold, gearbox, diff upgrades that make it way more and that's just to make it fast in a straight line. Suspension, arb's etc etc too to make it corner. Would love to have the coin to do it all mind you.

Depending on what they took off the block and head I wouldn't have thought you'd have any contact issues with 272's, although I'm not sure on the spec of the racemax, I have GSC S2's on mine. You can trial fit and just turn the engine by hand to check contact, slowly obviously. I'm sure you already know all that though.

edit: Meant to say it's worthwhile doing the Oil and water pump while you are there too. It's the only regret I have with my drop in is that I'm still on the original oil pump.

[philthy]

Just read your post the BigD

[philthy]

First post updated

[BigD]

Just read your post the BigD
Found the car - a low mile Evo 6 RS, HKS suspension, massive ARBs, HKS ecu, hardpipes, rose jointed arms, a good base car, picking it up in the next week or so.

Im planning on using a geekmapper with the standard ecu however as the cold start map on the HKS is pants allegedly.
Shopping list after the engine out of that is sold will be turbo and fuelling.
The lift on the 272s is about 0.85mm higher than standard, hopefully it should cause too much problems but worth checking!

Will be getting stuck into this tomorrow hopefully so will update!

Sounds perfect.

You'd probably get away with a Bosche in line pump depending on your turbo but for around 500bhp that should do. Or just go for the twin bosche setup. Not that I really know all that much about it. Yeh I've heard the HKS has it's issues.

Did the K1 rods not come with ARP's. My Manley's did. I assumed they all would.

[philthy]

I had originally bought some eagle rods which came with ARP 2000s then I got the K1s without. I sold the Eagles after some talks with people in the know and bought new bolts for the K1s because when I torqued them for the second time they went a bit soft - thought it was best to swap them for peace of mind

You are running a Gen1 FP Green and walbro IIRC? Im not sure what to run, lots of new ball bearing core turbos coming out soon so might wait for some results. it will take me a while to get round to fitting this engine anyway. Bosch 044 is looking like the best option, will see if the car comes with anything fitted, might get a nice surprise