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Mit_4G63 DSM Mods

Design Modifications
to the
Mitsubishi 4G63 (DSM- USA) Engine

By Tim Hoffman

After replacing the engine in my good friend Todd Girvin's 1993 Eagle Talon TSI due to very poor dealer work, I had the opportunity to thoroughly examine his dead engine and compare it in detail to my spare 1990 turbo parts engine. This page describes the differences that I have found between the two. Hopefully someone will find this useful when swapping engines from different years or just upgrading / replacing individual components.

Keep in mind that I've only had detailed access to a 1990 engine (serial #HW8597) and a 1993 engine (serial #NN5387) engine outside of the cars. If your serial numbers are close to these then your engine is probably similar, but not necessarily so. There may be (and probably are) a host of other modifications that were made that are not on the list. The split between engine models seems to be at serial #NH0001. Any lower number and it is the older engine model. Any higher number and the engine is the newer model. The dealer's parts books reflect this also. If anyone can get a parts book from them I want it!

If anyone has additional details about the 4G63 engine I would like to hear from you! I want to further develop this page into a parts compatibility and interchangability guide.

Thanks to everyone who has already contributed to this page! Tim Hoffman

 

Interesting Facts

Contrary to popular belief, this engine did not appear first in 1990!

I've hear rumors that it may have been fitted in some form
I also found a bit of information in Humphries'
Automotive Supercharging and Turbocharging Systems:
 

Make

Year

Engine

Galant

1987

4G63TI

Eterna

1988

4G63TI

 

4G63TI

  • Size: 1.997

  • Form: Inline-4

  • Max Power Output: 151 kW (202 HP)

  • RPM @ Max Power: 5000

  • Max Torque: 254 Nm (187 lb-ft)

  • RPM @ Max Torque: 3000

  • Compression Ratio: 7.8:1

  • BMEP: 18.9 kg/cm2 (269 psi)

  • Supercharger: Mitsubishi Turbo, Watercooled

  • Air/Air Intercooler

  • Pressure Control: Wastegate

  • Direct Port Injection

  • Emissions: Catalytic Converter, Oxygen Sensor

Manifolds

 

Component

1990 Engine

1993 Engine

Exhaust Manifold Gaskets

Standard composite gasket similar to a head gasket in construction

Two-layer thin metal gasket.

Exhaust Manifold Studs

All exhaust manifold studs are the same diameter (M8).

The two lower studs on the ends are larger (M10) than the rest of the studs (M8).

Throttle Body


 

Some of the throttle body sensors have been repositioned.

Throttle Body Mounting Studs

Mounting studs are located in the front (closer to engine) positions and bolts in the rear.

Mounting studs are located in the rear positions and bolts in the front. This makes installation of the manifold brace easier.

 

Cylinder Head

 

Component

1990 Engine

1993 Engine

Camshaft Angle Sensor


 

Has been updated with an integral connector (no wire with a connector on the end of it). This connector is incompatible with the 1990 harness. Both types of sensors will physically fit in either the 1990 or the 1993 cylinder head. I'm not sure if they are electrically compatible yet. Internally the photosensor slots may have been moved around.

Camshaft Timing Sprockets

Black finish

Metallic finish

Cylinder Head Bolts

M10 bolts with 8mm Allen heads (inset hexagon).

M10 bolts with 12mm 12-point heads.

 


Block

 

Component

1990 Engine

1993 Engine

Block


 

There are numerous changes to the block.

Bearing Inserts


 

Both the main and rod bearing inserts are narrower than the 1990 versions. Because of this they are no longer interchangable. I have found that the manufacturers I've tried to buy bearings from do not show a difference for 93-94 engines. They still think the 90-94 engines are all the same! Ignorance is such bliss...

Connecting Rods

Identification number is G6

Identification number is ??. The main portion of the rods are thinner than the 1990 rods. There appears to be less metal on the big end also. This should result in a significant weight reduction.

Crankshaft

The "big end" (where the flywheel is) has 6 bolts.
 

  • The big end has 7 bolts and is about 8mm larger in diameter than the 1990 crankshaft.

  • Weighs less due to smaller counterweights.

  • Main and rod bearing journals are narrower than the 1990 journals.

Crankshaft Big End Oil Seal


 

The seal is about 1/4 larger in diameter than the 1990 seal.

Crankshaft Main Bearing Caps


The #1 and #2 bearing caps are connected together (as are the #4 and #5 caps) with one thick metal beam that is situated below the center of the caps. The #3 thrust bearing cap is completely separate from the others.

All bearing caps are connected by two thick metal beams that are situated below and to the left and right of the caps (when looking at the engine from either end).

Flywheel

6 bolts. Identification number 63GT is cast into the flywheel on the engine side.
 

7 bolts. Identification number 63TK. The diameter is about 8mm smaller than the 1990 flywheel. The clutch is exactly the same size, however.
Note: This could be a difference between FWD and AWD. Anyone know?

Oil Cooler

There are two threaded ports for an external air-cooled oil cooler. There are two smaller access ports that are blocked with large allen head plugs.

Has a water-cooled oil cooler bolted between the housing and the oil filter. The external cooler ports are gone, but the two smaller access ports are still there.

Oil Pick-Up Tube


 

The shape of the pickup screen has changed and the pickup tube extends further into the oil pan by about 15mm.

Oil Pump Gears

The gears are straght cut. This accounts for the whine sometimes heard when first starting a cold engine.

The gears are spiral cut, thus eliminating the former whine at startup.

Oil Pump Gear Cover


 

One of the 5 mounting bolt holes has been moved relative to the 1990 version. The rest remains the same. Because of this modification the two years are no longer interchangable.

 

Oil Seal Case

The case has a lip around the outside of the oil seal that makes it necessary to remove the case to change the oil seal.

The case is modified to accept the larger sized oil seal. The oil seal can be removed from outside the engine without removing the case. The cases are not interchangable between blocks of different years.

Pistons

  • Turbo piston identification number is G63T

  • Non-turbo piston identification number is G63

Turbo piston identification number is G63TK (lighter than G63T?)

Front Casing


 

There are several modifications to the front casing making the two incompatible. I will list them soon.


Other Components

 

Component

1990 Engine

1993 Engine

Ignition Coil Unit

Has a small electronic unit labeled "Tach Interface" attached. The harness connector has 4 pins.

Does not have the "Tach Interface" and has a 3 pin connector.

Ignition Power Transistor Unit

5 pin connector.

6 pin connector which includes an output for the tachometer.

 

Sources of this information other than the complete disassembly of two engines ('90 and '93):

1 Laser/Talon Technical Manual, Chrysler Tech Authority
2 Haynes Manual #2097 covering the Plymouth Laser, Mistubishi Eclipse, and Eagle Talon 90-94. Note that this manual has quite a few errors! Be Careful!
3 1993 Laser/Talon Service Manual, Chysler
4 1990 Eclipse Service Manual, Mitsubishi
5 Import Car Manual 1990-1994, Chilton Book Company
6 Mitsubishi Eclipse 1990-93 Repair Manual, Chilton Book Company
7 Automotive Supercharging and Turbocharging Systems, John Humphries, Motorbooks International

 

With special thanks to Tim Hoffman, DSM'er extraordinaire.

 
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