Monday, June 17, 2013

Piston Ring Gaping for the 4G15 Mivec Rcolt Motor Rebuild




From the Mitsu Service Guide - 4G15 Mivec
Piston ring side clearance in ring groove mm  [LIMIT]
No. 1 0.03 − 0.07 [0.1]
No. 2 0.02 − 0.06 [0.1]





Measured all the pistons, used the small box to get them all at the same height



Use two wrist pins to square the piston ring in the bore






























Piston ring end gap mm
   No. 1 0.15 − 0.30 [0.8]
   No. 2 0.30 − 0.45 [0.8]
   Oil ring 0.20 − 0.50 [1.0]

Connecting rod big end thrust clearance mm
   0.10 − 0.25 [0.4]
Oil clearance at crankshaft pins mm
   0.025 − 0.040 [0.1]













CRANKSHAFT AND CYLINDER BLOCK
Crankshaft end play mm
   0.05 − 0.18 [0.25]
Oil clearance at crankshaft journals mm
   0.02 − 0.04 [0.1]
Cylinder block gasket surface warp mm
   0.05 [0.1]
Cylinder block gasket surface grinding limit (including cylinder head grinding amount) mm
   − [0.2]
Cylinder bore diameter mm
   75.50 − 75.53 [−]
Taper of cylinder mm
   0.01 or less [−]
Cylinder-to-piston clearance mm
   0.02 − 0.04

My Measurements of the Block
Bores Measurements
Averages 0.495 76.505 0.499 76.501 0.500 76.500 0.495 76.505
X is parallel to the crank 1 is 15mm from top deck
Y is 90degree rotation of the crank 2 is 2/3 down the bore
Pistons Diameter @ Skirt 76.42 76.42 76.42 76.42
Piston to Wall Clearance 0.080 0.075 0.075 0.080
Wiseco Recommended Clearance is  0.08889mm Bore size 3.012 inches 76.5048 mm
OEM Piston to wall is  .02-.04 mm
Std OEM Piston Bore 75.5-75.53 mm
Deck .05mm std 0.1mm limit
Top Ring Bore x 0.00500 inches *Application - Street Moderate Turbo/Nitrous
Second Ring Bore x 0.00550 inchens *Circle Track/Drag Race recommends .0055 & .0060
Therefore ring gap = [bore size (mm) / 25.4] * (ring bore)
Top Ring Gap 0.0150596 inches 0.382514 mm 0.015 inches rounded
Second Ring Gap 0.0165656 inches 0.420765 mm 0.016 inches rounded

We are running 3.5thou piston to wall clearance. Another friend went 4.5thou which isn't really needed due to the Wiseco composition.










































From the Mitsu Service Guide - 4G63
Install the piston ring into the cylinder bore. Force it down with a piston, its crown being in contact with the ring, to correctly position it at right angles to the cylinder wall. Then, measure the end gap with a feeler gauge. If the ring gap is excessive, replace the piston ring.

Standard value:
No. 1 0.25-0.40 mm (.0098-.0157 in.)
No.2 0.20-0.35 mm (.0079-.0138 in.)
Oil 0.20-0.70 mm (.0079-.0276 in.)
Limit:
No. 1, No.2 0.8 mm (.031 in.)
Oil 1.0 mm (.039 in.)





















































Friday, June 14, 2013

RnD Custom Pistons 4G15 Mivec - The Mission Starts Now - Finding a supplier!







Where does it start? I don't know. But here are a collection of assorted piston related diagrams and pictures.




























The bent rod/piston found in Adz car.
/bent-rod-z27ag-4g15-more-to-come.html












Can't remember where i found these CP piston photos.








Spool rods i believe




















Decked block with the pistons installed.











Machine shop










BFM/Full blast piston kit with coated skirts.













More CP pistons photos.









The bent rod :(






























A typical sheet you have to fill out when ordering a custom piston.







Various parts of a piston

















A bit annoying that the stock OEM books don't go into more detail regarding the 4g15 piston. But yet they go into detail regarding the 4A91









I Found interesting information here:
http://z3.invisionfree.com/

4G15 - 75.5mm x 82.0mm
4G18 - 76.0mm x 87.3mm
S4PH - 76.0mm x 88.0mm

Regarding pistons, cranks, stroker kits and other various comparisons of the old 4G15 and other similar engines.






/40412-4g15-modify.html
4G15 bored 2 1.6 not 2 say cannot but the reliabilty is the main concern..
as 4G15 bore n stroke is 75.5mm x 82mm while the 1.6 piston is 81mm...tat means boring as much as 5.5mm more 4 each

Rod length: 131mm
Big end diameter: 45mm
small end width: 19.9mm
big end width: 19.9mm
small end diameter: 18mm

Finished Bore Size:
 76mm
Stroke:
 82mm

Flat Top Piston
Material: 4032

* evans tunning a youtube user that makes a decent engine rebuild video

Sample Piston Scan:

Custom Manufacturer Pistons:

http://www.rosspistons.com
http://www.jepistons.com
http://www.ariaspistons.com
http://www.wiseco.com/
http://www.cp-carrillo.com
http://www.mmsonline.com/articles/racing-to-create-custom-pistons
http://www.diamondracing.net

Thursday, June 13, 2013

Oil Cooler? Stainless Fuel Lines? Conversion to AN Fittings for the RColt

Previous install of the fuel pump - /fuel-pump-install-z27ag.html
Then i had to move the reg for the MCS install /cusco-mcs-for-z27ag-fuel-reg-move.html

I have to relocate the Tomei Type S fuel reg so that i can install the Cusco Master cylinder stopper.

Fuel Reg Specs Tomei becareful of fakes
Tomei 185106 Fuel Pressure Regulator Adapter Nissan Subaru Toyota
Accessories:
- 2x AN6 to 1/8NPT (fuel reg side) Fitting
- 2x #8 Straight / 1/8NPT Fitting [in use at the moment]

My friend uses a Sard fuel reg. Looks like they also use the same fittings AN6 to 1/8NPT




Fuel Rail Adapter Specs
The fuel rail adapter used is the same one for the Skylines series.
I believe the actual item i use is from the RB26DETT BNR32/BCNR33/BNR34 (which has the ability to use AN6 fittings).
- 11mm diameter fuel rail insert nipple, 10mm long
- NPT1/8 thread
- 40mm bolt to bolt with 3.5mm movement







Current Setup
I have upgraded the fuel pump and have a Type S Tomei fuel reg, also with barbed fittings.
At the moment i am using a barb outlet 8 mm / 0.314 inch on the  1/8" female ports of the fuel reg.
Therefore i need 2x AN6 to 1/8NPT (fuel reg side) fittings
Fuel Hose - 5/16", 7.9mm






This is what i asked for - 
 - 4 x AN6 to 1/8NPT - fuel reg/fuelrail adapters
 - 4 x 6AN male to 5/16" tubing adapters (p/n: 165056ERL) - for fuel delivery hard line connection
 - 10 x 6AN female to -6AN hose adapters (p/n: 300106ERL) - join the hoses to the -6AN male fittings e.g. fuel reg in/out to fuel rail and fuel return
 - 3.5M x 6AN hose (200series PTFE for all fuels)
 - 1 x inline 6AN fuel filter

All up it costed about $300AU, I should have plenty of left overs to do two cars.

This is what i got - 
 4 - AF816-06-02 - Male flare -6an to 1/8" NPT
 4 - AF108-05 - 5/16 tube to male -6an adapter
 10 - AF101-06 - straight hose end -6an blue
 1 - AF200-06-4.5M - SS Teflon Braided hose -6an
 1 - AF609-06 - billet fuel filter -6an

Tools
- Wurth pipe sealer or equivalent e.g. Loctite liquid thread seal - used for the NPT threads not AN fittings
- 6AN Earl's 165056 - Earl's Hard-Line AN Tube Fittings
- Koul Tool
- Earl Fitting Tools e.g. vice holder
- 37 degree flaring kit
- AEROFLOW BILLET VICE SOFT JAWS ALLOY AF98-2001 - AU $37.20





Brands


There are a few brands of different fittings, some include:
- Russell
- Weiand
- Earl's
- Allstar
- Aeroquip
- Aeromotive
- JEGS
- MagnaFuel





Earl / Edelbrock Parts
- Earl's -6AN male to 5/16" tubing adapters (p/n: 165056ERL) - for fuel delivery hard line connaction
- Earl's -6AN female to -6AN hose adapters (p/n: 300106ERL) - join the hoses to the -6AN male fittings e.g. fuel reg in/out to fuel rail and fuel return (need 4 of these min)
- -6AN hose
- some fuel regs can be a 3/8 NPT therefore these use -6AN male to 3/8" NPT (p/n: 981666ERL) to adapt the 6AN female hose end to fuel pressure regulator
- my Tomei Type S fuel reg is a 1/8 NPT therefore Earl's (p/n: 981662ERL) -6AN to 1/8NPT FPR Adapter
- Edelbrock fuel filter w/ -6AN male ends (p/n: 8129)

Stock and Hardline Fittings At the moment i am trying to find a decent hard line fitting adapter (e.g. 165056ERL). Earl does one but I am also looking into Swagelok see here

Using the Earl fittings good for ~60psi http://www.anplumbing.com/page/16
You might also hear about yor-lok tube fittings which i believe are double ferrule compression fittings

I also came across an Aeromotive 15103 - 5/16'' MALE QUICK CONNECT TO AN-06 MALE


Installation Notes

extracted from stealth316
Assemble the AN fittings and adapters. AN fittings seal either by the close contact of the 37º flared ends or with o-rings. The threads themselves never seal AN connectors. Also, never use thread sealant or tape on AN threads. e.g. not supposed to use Teflon tape on AN fittings.

o-rings, you can buy from either Aeroquip or Earl's. Either BUNA-N synthetic rubber or Viton will work. Both compounds are compatible with most fuels. However, Viton is more scuff resistance, can last longer, and has a higher temperature rating (400ºF instead of 275ºF for the BUNA).

SS braid coupled with movement can wear through areas in your engine bay. Make sure it is not in contact with hoses or parts that could cause damage. I put wire loom on some of my lines.

Earls
"Fuel manufacturers may have added any number of new unpublished additives to their blends. It is therefore difficult to know how the tube compound used in the inner liner of our Perform–O–Flex or any other brand of elastomeric hose will react with a specific fuel. Because of the unknowns described above, we are unable to guarantee that the hose listed is the best possible product to use with any specific fuel. If in doubt use teflon lined hose. Not to be used with brake fluid". 

HondaTech Forums

Background on AN and NPT
http://www.anplumbing.com/page/1
"AN" (Army-Navy) Sizes were established by the Aerospace industry years ago and were designated O.D. of the rigid metal tube that each size fitting is used with. 
AN sizes range from -2 (dash two) to -32 in irregular steps, with each step equating to the OD (outside diameter) of the tubing in 1/16" increments. Therefore, a -8 AN size would be equal to 1/2" OD tube (8 x 1/16 = 1/2). However, this system does not specify the ID (inside diameter) of the tubing because the tube wall can vary in thickness. Each AN size also uses its own standard thread size.
Note that 37° AN and 45° SAE fittings and tooling are not interchangeable due to the different flaring angles. Mixing them can cause leakage at the flare.

"NPT" THREAD SIZES:
Some of the most popular adapter fittings shown in our on-line shop are AN to NPT adapters

Oil Filter Relocation

Oil Filter - Ryco Z436
Height Overall 66.00mm
Seal Diameter 64.00mm
Seam Diameter 69.50mm
Thread M20-x1.5-6H

Earls Oil Filter Relocation:
MITSUBISHI ALL MODELS 78-2002 VARIOUS
THREAD - M20 X 1.5
SANDWICH - 517
BYPASS - 1977
REMOTE - ANY

I got a quote on the AF64-2042 to do an oil filter relocation swap. But it was way to expensive plus it didn't have a thermostat $200+.

Other Thing on the Shopping List

Aeroflow Billet Radiator Filter/Filler - Part # AF64-2043

Grex Oil sandwich cooler adapter P#12401126
M20 x 1.50 -10AN Fittings (2 in & 2 out)

The thermostat open temperature ranges from 71deg~85deg Celcius.

Note: 3/4x16unf filter Required. The Female side going to the block will be M20x1.5, but the male side going to the filter will be 3/4x16UNF (which is a common thread on Nissan oil filters e.g. Skylines)

Possible Ryco filters (similar to the Z436):
                Height Overall Seal Diameter Seam Diameter
Z386 76.00mm         63.00mm         68.00mm **Closest to seal spec
Z443 66.00mm         66.00mm         71.00mm **Closest to height spec

Earl s Performance 502ERL Adapter, Oil Filter, Sandwich, Aluminum, Natural, 3/4-16 in. Thread, -10 AN O-Ring Inlet/Outlet

Manufacturers
http://www.aeroflowperformance.com
http://www.earls.com.au
http://www.anplumbing.com
http://www.hamburgersperformance.com/

Tuesday, June 11, 2013

Stripping Down A Broken Block - 4G15T


< My car :) Sleeping :(

If you have been following, a mate and I are in the process of building another 4G15. A recent discovery in the old crank was a gouge. We are not happy with it. It could be fine, it may not be fine.




Close ups of the head












More details here: /4g15-crank-installation-arp-main-studs.html
I bought a wreck awhile back under the impression the engine was fine. BUT! It was not, i think i got cheated. Under the timing covers was a cracked block :(
This is the tear down of that motor.





























I played around with my torque bar and tried to gauge how much more torque was required to get the head bolts to slip. I was just shy of 80nm. Sitting around the 70nm. The stock OEM bolts are measure by degrees and not nm.




Oil line from pump to head.




















The head had been sitting a long time. The head gasket is damaged due to the broken block.










Correct installation of the gasket







Back and side profiles of the engine.














Oil pump and water pump



















Sludged motor, prob from blown water jacket and been sitting for many years.























Crank looked ok from first impressions































Broken block :(
Another broken block here:
/4g15-mivec-long-block-disassemble.html


Diagram:
http://demo.saleepc.ru/mitsubishi/groups/gen/B80A2001A/Z27A/XNGFR8

Main Studs:
Mitsubishi 6 Bolt 4g63 (6 Pack) MD000235
10 BOLT,CYLINDER BLOCK FLANGE,10X69

OEM Crank Bearings:
 03018 MD332492 2003061 2004113
03018 MD332493 2003061 2004113
03018 MD332494 2003061 2004113
03018 MD332495 2003061 2004113
03018 MD332496 2003061 2004113
03018 1052A016 2005121
03018 1052A017 2005121
03018 1052A018 2005121
03018 1052A019 2005121
03018 1052A020 2005121


Big End Bearings:
03019 MD370354 2003061 2004113
03019 MD370355 2003061 2004113
03019 MD370356 2003061 2004113
03019 1115A081 2005121 2007123
03019 1115A082 2005121 2007123
03019 1115A083 2005121 2007123
03019 1115A084 2005121 2007123
03019 1115A085 2005121 2007123
03019 1115A423 2008011
03019 1115A424 2008011
03019 1115A425 2008011
03019 1115A426 2008011
03019 1115A427 2008011

Thrust Bearing:
03068 MD332719 2003061 2004113
03068 MD332720 2003061 2004113
03068 MD332721 2003061 2004113
03068 MD332722 2003061 2004113
03068 MD332723 2003061 2004113
03068 1052A021 2005121
03068 1052A022 2005121
03068 1052A023 2005121
03068 1052A024 2005121
03068 1052A025 2005121

Camskill Lifter Information:
MODEL NAME: MITSUBISHI TAPPETS/LASH ADJUSTERS - Tappets/Lash Adjusters X 8 - MD171130 MD376687

CA3A CB3A MIRAGE/LANCER 4G91 DOHC
CA4A MIRAGE 4G92 DOHC (NON MIVEC)
CB6A MIRAGE/LANCER 6A10 DOHC
CD5A CD5W LANCER/LIBERO 4G93 DOHC TURBO
CJ2A CK2A MIRAGE/LANCER 4G15 DOHC
CM5A MIRAGE/LANCER 4G93 DOHC TURBO
CQ2A CS2A MIRAGE/LANCER 4G15 DOHC
CQ5A CS5A MIRAGE/LANCER 4G93 DOHC
CU4W AIRTRECK 4G64 DOHC
DA2A CARISMA 4G93 DOHC
DE3A FTO 6A12 DOHC (NON MIVEC)
E52A GALANT 4G93 DOHC
E54A E64A E74A E84A GALANT 6A12 DOHC
EA1A EC1A EA1W EC1W GALANT/LEGNUM 4G93 DOHC
EA3A EC3A EA3W EC3W GALANT/LEGNUM 4G64 DOHC
EA7A EC7A EA7W EC7W GALANT/LEGNUM 4G94 DOHC
EC5A EA5W EC5W GALANT/LEGNUM 6A13 DOHC
F36A F46A DIAMANTE 6G72 SOHC
N61W N71W RVR 4G93 DOHC
N64WG N74WG RVR 4G64 DOHC
N84W N94W CHARIOT 4G64 DOHC
S33A S43A PROUDIA 8A80 DOHC
Z25A Z26A COLT 4G19 DOHC MIVEC
Z27A Z28A COLT 4G15 DOHC MIVEC

Notes 1 These are 3mm hole type

Manufacturers Part Numbers for REF ONLY CAMSKIT2093
MD376687
MD377239
MD171130
MD359419