Table of Contents
The 4G63 engine is renowned in the automotive world for its performance potential and tunability. This article outlines a step-by-step guide to building a 4G63 engine capable of producing 600 horsepower using forged components and Garrett turbochargers. Whether you are a seasoned mechanic or a novice enthusiast, this guide will provide you with the necessary steps to achieve your performance goals.
Understanding the 4G63 Engine
The 4G63 is a 2.0-liter inline-four engine that has been used in various Mitsubishi models since the late 1980s. Known for its robust design, the engine features a DOHC configuration and is capable of handling significant power upgrades with the right modifications.
Step 1: Gathering Components
Before diving into the build, it’s essential to gather all the necessary components. Here’s a list of what you’ll need:
- Forged pistons
- Forged connecting rods
- Performance crankshaft
- Garrett turbocharger
- Upgraded fuel injectors
- Aftermarket ECU
- High-performance camshafts
- Upgraded intercooler
- Exhaust manifold
- High-flow fuel pump
Step 2: Disassembling the Engine
Start by removing the engine from the vehicle. This process typically involves:
- Disconnecting the battery
- Removing the intake and exhaust manifolds
- Detaching the transmission
- Unplugging all electrical connections
- Lifting the engine out of the bay
Step 3: Preparing the Engine Block
Once the engine is out, it’s time to prepare the block for the new components. This includes:
- Cleaning the engine block thoroughly
- Inspecting for cracks or damage
- Machining the block if necessary
- Installing new main bearings
Step 4: Installing Forged Components
With the block prepared, you can now install the forged components:
- Install the forged crankshaft
- Fit the forged connecting rods with new bearings
- Install forged pistons into the cylinders
Step 5: Upgrading the Cylinder Head
The cylinder head is crucial for performance. Follow these steps:
- Inspect the cylinder head for wear
- Install upgraded camshafts
- Upgrade the valve springs and retainers
- Ensure proper clearance for forged pistons
Step 6: Installing the Turbocharger
With the engine assembled, it’s time to install the Garrett turbocharger. This process involves:
- Mounting the turbocharger to the exhaust manifold
- Connecting the intake piping
- Installing the wastegate and boost controller
Step 7: Fuel System Upgrades
To support the increased power, you’ll need to upgrade the fuel system:
- Install high-flow fuel injectors
- Replace the fuel pump with a high-performance unit
- Upgrade the fuel lines for better flow
Step 8: Tuning the Engine
After all components are installed, tuning is essential for performance and reliability:
- Install an aftermarket ECU
- Use a dynamometer to fine-tune the engine
- Adjust air-fuel ratios for optimal performance
Step 9: Final Assembly and Testing
With everything in place, reassemble the engine and prepare for testing:
- Reinstall the engine in the vehicle
- Reconnect all electrical and mechanical connections
- Start the engine and monitor for any issues
Conclusion
Building a 4G63 engine to achieve 600 horsepower is a challenging yet rewarding project. By following these steps and utilizing high-quality forged components and a Garrett turbocharger, you can unlock the full potential of your engine. Always remember to prioritize safety and reliability in your build.