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Discussion starter · #41 ·
All I want is a little luck with this damn thing. Got the piston rings today, fitted them and put the pistons back in. Get the torque wrench to tighten up the conrod cap nuts to spec (38ft lbs according to the 4g63 factory manual). Just as the wrench cracks the bolt just breaks clean off! I think WTF and double check the torque settings on the wrench. All is good so I pull that piston back out as I've got to get another bolt for it. Try the same procedure with conrod in cylinder 2. First bolt torques perfectly. Second does exactly the same as that first bolt!

So I've given up for the evening for fear of destroying all the rest of the bolts. So much for getting a good start on the rebuild tonight :(
 
Possibly. Wondering if I should replace the whole set of 8 of them, rather than just the 4 on the pistons that have broken.

Also, am assuming that I'm going to need a press or something to get the bolts out?
I would just to be safe. We had a block like that would break them if Not right. Then replaced them with other's we had laying around and worked out great.
 
Discussion starter · #50 ·
Christ, if I get a hammer close to this car I think I'm just gonna let rip on it. It's such slow going, mainly as any parts I need have to be ordered from mainland and take about a week to come in (i.e. I can't do anything now for a week until I get 8 rod bolts delivered to the Mitsu dealership).
 
Discussion starter · #51 ·
It lives!!!

After a huge effort this weekend and some help by one of the most knowledgeable engine-builders in Okinawa, I finally turned the key on the Evo and got it running again. Putting it together wasn't without incident though, including having the motor locked up solid when we tried to turn the crank by hand! But we sorted it out in the end and I'm feeling pretty good about it to be honest. It's taken and age and has been difficult, but I've doe a good proportion of the work on it myself and it's more than I ever thought I'd be able to do.

Have written a full write-up of the final stages of my rebuild on my site. I would copy and put it on here but would need to change some of the wording so it fits in here which I really am too tired to do! So if you have any interest at all then have a look here: http://soldave.ismysite.co.uk/biginjapan/the-evo-lives

Thanks to all those who have helped me with advice in the rebuild. Has been much appreciated :)
 
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