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How to Build Max-Performance Mitsubishi 4G63t Engines
Mitsubishi's 4G63t engine is among the most powerful engines ever in the sport-compact world. It's not uncommon to find one of these four-cylinder, iron-block, aluminum-headed, 2-liter turbocharged monsters making more than 1,000 horsepower with the right modifications and tuning - well above the 200-300 hp produced in the factory-made engines. Bolted into such cars as the Mitsubishi Lancer Evolution, Eclipse, and Galant, and the Eagle Talon and Plymouth Laser, the 4G63t has more than a cult following among sport-compact enthusiasts, who know and respect this engine's immense performance potential at the track or on the street.
Up until now, in-depth performance information on the 4G63t has been hard to find. For this book, author Robert Bowen went straight to the source, Robert Garcia of Road/Race Engineering in Santa Fe Springs, California. RRE is the most well-known and respected Mitsubishi turbo performance shop in the United States, and Garcia is its in-house engine builder. Mitsubishi enthusiasts will benefit from Garcia's expertise and be able to build better, stronger engines than ever before.
How to Build Max-Performance Mitsubishi 4G63t Engines covers every system and component of the engine, including the turbocharger system and engine management. More than just a collection of tips and tricks, this book includes a complete history of the engine and its evolution, an identification guide, and advice for choosing engine components and other parts. Profiles of successful built-up engines show the reader examples of what works, and the book includes helpful guidance for choosing your own engine building path.
Author Bios
Foreword
Acknowledgments
Introduction
Chapter 1: Introduction to the 4G63t
Sirius Engines
The 4G63t in the USA
The Lancer Evolution
The Evo in America
Finding and Buying a Turbocharged Mitsubishi
Engine Swaps
Buying a Core Engine
Maintenance
Power Goals and Budgeting
Other Factors
Paper Engine Building
Chapter 2: Basic Bolt-On Modifications
Expectations
Staged Tuning
Gauges and Instruments
DSM versus Evo Bolt-Ons
Air Filter or Air Intake
Exhaust
More Boost
Tuning or Chipping
Other Parts
Chapter 3: Turbocharging and Intercooling
Volumetric Efficiency
Enter the Turbo
Turbo Theory
Compressor Efficiency
Turbine Efficiency
Turbo Lubrication and Cooling
Ball- Vs. Sleeve-Bearing Turbos
Wastegates
Better Boost Control
Intercooling Theory
Intercooler Construction
Intercooler Spray
Chemical Intercooling
Bypass Valves and Blow-Off Valves
Stock Turbos and Intercoolers
Stock Turbo Manifolds
Turbo Swaps
Turbo Swap Collateral Damage
Intercooler Upgrades
Chapter 4: Intake and Exhaust: Making the Turbo’s Life Easier
Pre-Turbo Airflow
Turbo/Intercooler/Intake Plumbing
Throttle Body
Intake Manifolds
Insulating Spacers
Exhaust Systems
Exhaust Manifolds and Headers
Manifold Swapping and Porting
O2 Sensor Housing & Wastegate Plumbing
Exhaust Heat Control
Downpipes
Exhaust System and Mufflers
Emissions Equipment and Legality
Chapter 5: Fuel System
Octane
Fuel Injectors
Fuel Pressure Regulators and Gauges
Fuel Lines
Fuel Pump Needs
Fuel Pump Wiring
Upgraded Pumps
Chapter 6: Engine Management and Tuning
Stock ECU Sensors
Limits of the Stock ECU
Why Tune the ECU?
Hacking the MAS and MAS Swapping
Piggybacks and Airflow Computers
MAF Translator
Blow-Through MAF
Advanced ECU Fooling (Speed Density)
Reprogramming the Stock ECU
Standalone Engine Management
Building Your Own ECU
Choosing an Engine Management System
ECU Tuning and Emissions
Ignition System
Ignition Modifications
Tuning Basics
Chapter 7: Cylinder Heads, Camshafts and Valvetrain
Head Swapping
Head Gaskets
Head Bolts and Studs
Port Flow
Combustion Chamber
Valvetrain
Camshafts
Cam Drive
Chapter 8: The Bottom End
Stock 4G63t Bottom Ends
Machining a Block
Oiling System
Pistons, Pins and Rings
Compression Ratio
Connecting Rods
Crankshafts
Engine Bearings
Crank Walk
Source Guide
Mitsubishi's 4G63t engine is among the most powerful engines ever in the sport-compact world. It's not uncommon to find one of these four-cylinder, iron-block, aluminum-headed, 2-liter turbocharged monsters making more than 1,000 horsepower with the right modifications and tuning - well above the 200-300 hp produced in the factory-made engines. Bolted into such cars as the Mitsubishi Lancer Evolution, Eclipse, and Galant, and the Eagle Talon and Plymouth Laser, the 4G63t has more than a cult following among sport-compact enthusiasts, who know and respect this engine's immense performance potential at the track or on the street.
Up until now, in-depth performance information on the 4G63t has been hard to find. For this book, author Robert Bowen went straight to the source, Robert Garcia of Road/Race Engineering in Santa Fe Springs, California. RRE is the most well-known and respected Mitsubishi turbo performance shop in the United States, and Garcia is its in-house engine builder. Mitsubishi enthusiasts will benefit from Garcia's expertise and be able to build better, stronger engines than ever before.
How to Build Max-Performance Mitsubishi 4G63t Engines covers every system and component of the engine, including the turbocharger system and engine management. More than just a collection of tips and tricks, this book includes a complete history of the engine and its evolution, an identification guide, and advice for choosing engine components and other parts. Profiles of successful built-up engines show the reader examples of what works, and the book includes helpful guidance for choosing your own engine building path.
Author Bios
Foreword
Acknowledgments
Introduction
Chapter 1: Introduction to the 4G63t
Sirius Engines
The 4G63t in the USA
The Lancer Evolution
The Evo in America
Finding and Buying a Turbocharged Mitsubishi
Engine Swaps
Buying a Core Engine
Maintenance
Power Goals and Budgeting
Other Factors
Paper Engine Building
Chapter 2: Basic Bolt-On Modifications
Expectations
Staged Tuning
Gauges and Instruments
DSM versus Evo Bolt-Ons
Air Filter or Air Intake
Exhaust
More Boost
Tuning or Chipping
Other Parts
Chapter 3: Turbocharging and Intercooling
Volumetric Efficiency
Enter the Turbo
Turbo Theory
Compressor Efficiency
Turbine Efficiency
Turbo Lubrication and Cooling
Ball- Vs. Sleeve-Bearing Turbos
Wastegates
Better Boost Control
Intercooling Theory
Intercooler Construction
Intercooler Spray
Chemical Intercooling
Bypass Valves and Blow-Off Valves
Stock Turbos and Intercoolers
Stock Turbo Manifolds
Turbo Swaps
Turbo Swap Collateral Damage
Intercooler Upgrades
Chapter 4: Intake and Exhaust: Making the Turbo’s Life Easier
Pre-Turbo Airflow
Turbo/Intercooler/Intake Plumbing
Throttle Body
Intake Manifolds
Insulating Spacers
Exhaust Systems
Exhaust Manifolds and Headers
Manifold Swapping and Porting
O2 Sensor Housing & Wastegate Plumbing
Exhaust Heat Control
Downpipes
Exhaust System and Mufflers
Emissions Equipment and Legality
Chapter 5: Fuel System
Octane
Fuel Injectors
Fuel Pressure Regulators and Gauges
Fuel Lines
Fuel Pump Needs
Fuel Pump Wiring
Upgraded Pumps
Chapter 6: Engine Management and Tuning
Stock ECU Sensors
Limits of the Stock ECU
Why Tune the ECU?
Hacking the MAS and MAS Swapping
Piggybacks and Airflow Computers
MAF Translator
Blow-Through MAF
Advanced ECU Fooling (Speed Density)
Reprogramming the Stock ECU
Standalone Engine Management
Building Your Own ECU
Choosing an Engine Management System
ECU Tuning and Emissions
Ignition System
Ignition Modifications
Tuning Basics
Chapter 7: Cylinder Heads, Camshafts and Valvetrain
Head Swapping
Head Gaskets
Head Bolts and Studs
Port Flow
Combustion Chamber
Valvetrain
Camshafts
Cam Drive
Chapter 8: The Bottom End
Stock 4G63t Bottom Ends
Machining a Block
Oiling System
Pistons, Pins and Rings
Compression Ratio
Connecting Rods
Crankshafts
Engine Bearings
Crank Walk
Source Guide
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