I pulled a 2.4 SOHC 7 bolt 4G64 from an Expo wagon probably a year ago from the junkyard, think it had a little over 100k. As a matter of fact I remember the day very well because I had recently got my Colt running and got lightly rear-ended by a lady that wasn't paying attention on the way home. I tore the engine down shortly after and sent it off to the local machine shop to have the block baked and cleaned and the cylinders honed, along with a light polish on the crank. Everything was in mint shape. So then I hosed it all down with WD40, put it all in plastic bags and let it sit in the corner of the shop for a while. Recently I decided to dig it out and get to work. Here's where I am so far.
Block painted with new freeze plugs and also new plugs pressed into the deck for the DOHC conversion.
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Now it was time to clean up the internals. No idea where I learned about this stuff at but I wish I'd have known about it years ago. It's around $19 at Wal-Mart and you can thank the late night stockers for the huge dent
.
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First test was a piston/rod combo. If you place one upside down you can get two in there at once. Let it sit overnight and took them out the next day. Shot them with carb/choke cleaner and I was amazed at the results.
Before:
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After:
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I still had to break an old ring and clean out the ring lands, then soaked them again and they came out looking new. Much less work than my last rebuild where I used a soft wirewheel on my bench grinder to get the pistons clean and still couldn't get to the hard to reach crevices.
I had excellent results with Enginetech parts from Rockauto on my last rebuild for rings and bearings so I placed another order for standard parts. The rings were made in Japan and the bearings in Israel. I want to say it was around $80 shipped for the rings, rod and main bearings. Hard to beat. Plastigauged the bearings and they were within spec, same thing with the rings, the gaps were within spec. I won't bore you with pics of the build, mainly because I was trying to focus and my hands were oily and I didn't take any
. Here is a pic with it assembled and some other parts painted and mounted.
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My oil pan was trashed and I searched and searched for a good 2g turbo oil pan with no luck. A 98 Galant showed up at one of the local yards and Thank God it was mint. About 20 min and $19 later I had what I needed. I found a no weld oil return fitting on ebay and decided to give it a try. Looked like a quality piece and only required one hole to be drilled, I can handle that. So I had an old dented turbo pan to take measurements from, transferred them over to the new NA pan where thankfully Mitsu decided to leave the flat spot for the oil drain mounting flange. Carefully drilled a pilot hole and worked my way up with a uni-bit.
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de-burred the inside:
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Armed with my trusty Harbor Freight angle grinder and a wire wheel I tackled the 20 y/o sealant. This is by far the easiest way I've found to remove that crap.
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It probably took ten minutes total to get it all off using this method vs an hour or more using a razor blade. Plus this cleans it way better.
before/after:
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So after a thorough clean I used my DA sander with some 180 grit paper to remove any scratches in the paint on the bottom of the pan.
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Some VHT high heat engine primer and semi gloss black:
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After letting the primer dry for an hour or so I lightly went over it with a scotchbrite pad, then the black paint.
Good as new:
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