How to remove pins from a 4G63 DSM ECU Connector

The other day, I was asked about how to remove pins from a Mitsubishi 4G63 (DSM) ECU connector. I had made a video in the past about this, but I knew I could do better. I yanked an ECU connector from my trash pile, and sliced that sucker in half. That way I could show the magic inside. The way that I have always removed the pins is with a custom built hair clip stolen from my wife’s hair. I just remove the hard plastic from the end of the hair clip, and bend it at a ~30 degree angle. This is the perfect tool for removing this style pin. Watch the video and see.

This is a Compound Turbo on a 4G63 4 Cylinder Engine

A friend of mine is building a fresh compound turbo setup for his race car. As you can see, it’s looking pretty serious.  His previous experiments have attained him 7 second quarter mile passes at 180+ miles per hour.  All of this from a factory-built 4 cylinder 4G63 turbo engine block, and a whole lot of boost.  Kevin Jewer is his name and he is well known in the DSM community for piloting his rear wheel drive Talon faster than nearly all DSM’ers have before him. I have no doubt that he has an excel spreadsheet that has already proven this turbo combination with hundreds of quarter mile passes.  That is what makes Kevin so damn consistently fast. He understands what the engine is really doing, and why.  He measures pressure, temperature, and timing of every moving part during every 1320 pass.  That data is then added to a spreadsheet and locked away, probably in a safe with chains around it, and an ill-tempered honey badger guarding it. With thousands of passes and endless amounts of data stored away, Kevin can accurately predict what future engine combinations will produce for airflow, temperatures, and of course horsepower.  This compound turbo 4G63 combination looks like it belongs on an engine with three times the displacement, and it is leaving many people, including myself, on the edge of our seats for the 2015 racing season.

For those of you that just want to see the damn car already – here it is, filmed by Chad from URaceIFilm.com

This is how I rebuilt my 4 cylinder turbo 4G63 cylinder head.

Not too long ago I had a 4G63 cylinder head with valves that were leaking like crazy. I pulled the head from the block and found the most carbon build-up that I have ever come across. The solution – rebuild the head of course!

I began by removing the stock turbo 4G63 cams.
Camshaft removal

I then organized all of my lifters and rockers, because keeping the parts in the same spots is ideal.

Each valve spring is held in with two “keepers”. Over time, the keepers become stuck in the spring retainers. If you tap the spring retainers with a socket, it shocks the keepers, and breaks them away from the retainers. This makes your life much better.

4G63 heads require a special valve spring compressor tool. I didn’t take a picture of it for some reason, but the moral is – you need to remove the keepers from all of the valves.

Don’t forget nourishment. Your body needs it if you want to be at the top of your game.

For fun, look at the valves in cylinder #1

Now look at them opened

Look at the valves in cylinder #2

Now look at them opened

Look at the valves in cylinder #3

Now look at the opened

Look at the valves in cylinder #4

Now look at them opened

Pretty bad carbon build up, don’t you think?

This is what they look liked before I cleaned them with a wire wheel.

This is what the valves look like after the wire wheel (same valve!).

Once cleaned, each valve needs to be lapped into the seats with valve grinding compound.

New valve seals should always be installed, because they are cheap, and you are already this deep into the repair.

I like to test the valves to make sure they hold water. If they hold water they should hold air just fine too. If the water leaks out, then you have a damaged valve or need to lap the valves better. In my case, I had 2 valves that were damaged beyond repair. The other 14 were A-okay!

Almost ready to reinstall!

Lastly, everything needs to be torqued properly. Make sure you use a good torque wrench because this is one of the times it really matters.

And that is what it’s like to rebuild a 4G63 turbo cylinder head that is packed with nasty carbon build up. The whole project was pretty cheap (less than $50), and took a few hours. Next time, maybe I will clean off my work bench first so that I don’t look like a car-part hoarder.

Must Watch – 1G AWD DSM Doing A Reverse Wheelie

There are some guys in the same car club as me with some wickedly fast cars. This is one of them. It is Nick Stack’s 1G DSM that is capable of running 9 second, 150+ mph quarter mile times. The video was taken by Chad Saindon at New England Dragway last week. Needless to say there were a couple of little “bugs” to work out this season. It turned out to be a damaged injector clip from what I’m told.

Under more normal conditions, he cuts 1.3 second 60 foot times, and rips off 9’s like it’s his job. Here is a recent incredible 60 footer, which then resulted in some shifting issues. Notice the speed though when he crosses the finish line. Got horsepower much?

But then you are probably saying – does this guy ever make a full pass? Well, yes. Of course he does. Here is one from 2012. He will be faster this year.

When Your Race Car is Also Your Work Truck and Your Daily Driver.

They say that you need three vehicles, a daily driver, a race car, and a project car. Personally, I think a work truck belongs in there too, because how will you move sheetrock in a race car?