Hyundai Assembly 1 - Blueprint Everything

HOLD ON TIGHT! HERE WE GO!
We begin the blueprint and assembly on my 1992 Hyundai Elantra's bastardized 4g63. The parts used in this are from a mash of different brands and models outside of the typical 2.0L 4g63, but the specs and standards I am following for its assembly are for the 2.0L DOHC.
If you want to follow along in your service manual to verify what I've done here in this video, the processes we cover here detail pages 11C-95 through 11C-105 of the 1g Overhaul manual. I would prefer you not rip them from the binding and throw them away, relying only on this video for instruction... but rather use this video as a motivational guide, and as a demonstration of the techniques involved in those sections.
You gotta do the cooking by the book.
I never had any intention of making instructional videos on this particular car, but after it blew up I slowly realized it's actually a better case study for how a 4g63 ticks than anything else in my driveway. There are several reasons for this. One being that it's a mix of parts that shouldn't be bolted together, and the other is that many of you watching my videos aren't trying to build a 600hp engine out of aftermarket parts. You're trying to put back together what used to be your daily driver. This car covers those bases. Don't think for a second I won't go through this same trouble and level of detail for the GSX. I will. When I do, having this information in this video will give you a better understanding on how and why I do things the way I do when I get there.
This was the shortest I could condense this video. I've never uploaded a video this long, and I hope I never have to do it again. It took a month to create on cutting-edge equipment, 16 hours to export, and 9 hours for KZbin to process. My script for the voiceover is 6 times longer than the whole script for the movie Pootie Tang. 6 times. Longer. Than a Hollywood movie.

[@treblarefils]

The amount of info in this 41 min video is equal to a 1 semester engine class haha. Awesome video!

[@pauloshea3741]

This is one of the best automotive videos here on youtube. No bullshit, straight to the point.

[@TomsTurboGarage]

The level of detail, amount of knowledge and sheer effort taken to document this process is just amazing. Excellent as always Jafro and thank you for sharing your skills!

[@Jafromobile]

Thanks man! I'm just doing what it says in the service manual. ;) The service manual is our friend!

[@0ddhair]

***** I couldn't decide where to post this, but thanks Jafro, and you too, Tom (though your jumper has a different name on it...) for your different but great contributions. Thanks to you guys and some others like Eric the car guy, I'm getting much more confident ripping into engines. I'm messing with a Honda H22A4 in a bone-stock 2000 Prelude base model, but the broad similarities between the two 4-cylinder engines have helped quite a lot. I literally used Plastigage for the first time in my life this week, and the tolerances were good!

[@TomsTurboGarage]

David Weatherly Thank you David and good luck with your Prelude! I agree that videos like Jafro's and Eric's are extremely helpful as they are fun to watch. Have a good one!

[@jdjdvgfkgv916]

David Weatherly

[@joelperez4060]

Tom's Turbo Garage mm bu. Cu

[@revolutionzerox]

woke up today to see a 40 min on shortblock assembly.. love it. some watch sat morning cartoons, I watch tech vids. keep up the good work.

[@robertomiguel6174]

Watching this video is way better than browsing a service manual.

[@HoweDoYouDo1999]

This man should get a Grammy on spitting car facts 😂 my man has me sitting in the classroom right now 😂

[@Saileahgaz]

So much time and effort! 410,000 people owe you thanks. Myself included. So thank you!

[@koztowz]

Three 'Sloppy Mechanics' references and a leaky 'o-ring' joke as you were checking loose rings; I am left in awe after every one of your videos Jafro, thank you.

[@tonkatoytruck]

Just got back from the Renaissance Festival and camping for four days. Haven't even checked my email yet but I did find you latest video!!!!! Thanks for sharing your time and your knowledge freely, my kind sir.

[@jalopyjoe3069]

I'm in the process of doing my 1st 4g63 bottom end overhaul. And I've watched these videos at least 3 times. Just wanted to thank you for the detail and effort you went through to document all of this. It's made this a go to source of info for me and many others. That makes these videos timeless. As long as there's still a few DSM's on the road, people will have this resource. Thanks!

[@ivanvera7027]

Great video. Years back I had a 6 in line Ford engine. Did not have much money so I took everything apart, clean all and then install with new standard rings and new bearings. Took no measurements and ran for 100,000 more miles. I was lucky. You are doing it the correct way.

[@brucebaxter6923]

Just discovered this series. Very well done and presented. Shows great detail without complexity that most people are unable to deal with.

[@anthonywendt5834]

I can't stop watching your videos, especially since I'm laid off until march! Your getting a % of my NJ unemployment check. Thank you for everything you do!

[@JETZcorp]

See all those wee holes in the piston oil ring grooves? Those are there to allow oil scraped by the rings to flow back down into the motor. Why point this out? Well, I happen to own a 1.9L Saturn, and like all 1.9 Saturns, it burns a ton of oil. That's because Saturn didn't bother to add those wee little oil ring drain holes in their pistons. Therefore, if you fail to use a good synthetic oil that can resist high heat AND change the oil often enough on a Saturn, the groove will fill with baked carbon crust, seizing the ring and preventing it from doing its job. But, if you treat your Saturn like a two stroke and top the oil off constantly, it'll happily go to 300,000mi. That's also why Craigslist is littered with Saturns that have engine issues; someone let the poor thing run down to 0qts. Prime candidates for Chumpcar or LeMons! Now you're a Saturn expert. Tell your friends.

[@cljvikingpride19]

So I just wanted to say thank you so much on this series, and everything else related to this engine on your channel, it's really given me a clear idea on my build. I just bought a 1G Talon Tsi AWD for super cheap, and I'm about to pull the engine out for a rebuild. Seeing it all done like you have and seeing specs, part numbers, is probably going to save me days worth of time getting it back on the road. So again, thank you!

[@EdwardAlcala]

I really like the way you describe everything you do while I see the footage. All the details, specs, and instructions are great and not getting me lost. Keep up the good work I'm always watching your videos and waiting for more!

[@Jafromobile]

+Robert Ballard your replies are disabled. Look closely at the set again. Only half the shells should be grooved on the mains. If you haven't cut the plastic open, it will appear as though all of them are grooved. The groove meets up with the other half of the bearing shell, and the groove extends to the oil holes, but it shouldn't go all the way around. If you've already cut the plastic and looked at all of them, and they are indeed grooved, then I would not use those bearings if the groove is full-circumference. Not on a 4g63 anyway.

[@specialized29er86]

lOVE that sense of humor, time and money.

[@beekeeper6063]

I am speechless at the amount of knowledge you have...walking encyclopedia :)

[@hectormoreno1449]

Excelent informacion,very clean thank .

[@xXsk8er559Xx]

I am new to this engine building simply because I never really took the time to read or search for information. I've been doing research on completely disassembling and assembling an engine for a month now with my service manual and the web. but coming across your page has motivated me even more to keep learning more. such an educated guy here not to mention Hilarious (26:20)..

[@TaylorMiller_the_Figuresk8er]

Great job on the video! It really doesn't matter what engine you're building, the concepts are the same. It was a great walkthrough on what it takes.

[@ripplemaker1]

"You can just throw that right out the window in my case, this thing has been Ron Jermeied..." bahahahah! So glad I found this channel!

[@jboada9419]

Thank you Jafro for sharing your proven engine service experience. Excellent engine overhaul video production, hats off to you.

[@molsenice]

I have watched this vid a bunch a times, I just noticed the BOX of calipers - yo man CHAD RULES!!

[@Jafromobile]

molsenice Chad is a better guy than everyone but you, me, and his grandpa give him credit for.

[@alexcockerill]

I just read your description and wow. We all appreciate your time and effort!!

[@markfortin7853]

I like the bearing swap trick to adjust the plastigauge measurements.

[@wwjoshdew]

I'm just impressed that some checked the description. You'd be shocked how many people don't bother reading it or click the "Show more" text to see everything. 16 hours is crazy! haha. A 12 Core Mac Pro with Hyper Threading (24 virtual cores) would chew this footage up and spit it out. But that's 10 Grand for a maxed out model. I wish you had lived closed to St Louis where my car broke down and still is... I would of gladly paid you whatever you asked for, to fix my car. :)

[@Jafromobile]

And for you I think I might have been willing to do it. :) But you still wouldn't have it back. :( Did your make and model have an interference engine? Edit: I'm rolling with 16 2.4GHz virtual cores rignt now. My how obsolescence occurs quickly.

[@wwjoshdew]

***** yup. IT was a dual overhead cam engine and it was in fact an interference engine. He's got it running and everything now. Just gotta give him 2 grand plus the additional fee to replace an oxygen sensor that went bad right before it died. We'll head up there Monday.

[@justinpierce93]

***** I personally wouldn't want the new Mac pro nobody likes there computer to look like a trash can lol not been impressed with there bad for the earth book pro you can't even replace the battery when the battery dies it will be trash,I like the PowerPC era of apple

[@Jafromobile]

Until you've used one... man... you have no idea. It reads and writes a gigabyte a second. Nothing else in the consumer market is keeping pace with that right now. Nothing. It could be in a plastic Hello Kitty enclosure and I'd still want one at home. It's astonishingly fast.

[@MinimalistMotoLife]

always need more power, think ridiculous like dual $3000 intel xeon 12 core server CPUs with over 256gb of RAM, 4 way SLI GTX 780 TI graphics... and linux for the maximum efficiency. hackintosh or a virtual machine if necessary. that kind of money grows on trees right? . i have always used (2 stroke)premix for assembling jugs and slugs, it's designed to be in a combustion chamber and it smells great. the ending was great Jafro

[@puppynosee]

Wow. The work you do in putting these videos up is astonishing. Thanks for all the hard work. I would rather see one well done video every month or two than a crappy, slapped together with little to no thought every other day. quality over quantity.

[@thesickhorseranch1930]

Awesome video, thank you for the work you put into these. I especially like the comparisons you make from your application to a daily driver application, explanations like that go a long way on the "why?" side of things.

[@charliemartin9156]

You're an easy builder for real that blesses me thank you so much it's been a long time I need the refresher course I have a new crank new bearings into the machine shop they said the cylinders are good I have new Hastings cast-iron rings I wish I would've kept the rings that were in it because I can see now that the law and went out in a Kia Hyundai 2.4

[@dasungahn]

is this guy......king of everything ...about engine..

[@robertodelafuente487fuenteyay]

This guy is a f... guru. I love the way he explains every little detail. I am subscribing and following 100 %

[@wwjoshdew]

31:31 Haha! *IT WAS THE CHAIR*. Then your continued story about editing out farts and the recording light... That was awesome! :)

[@heyitschinoable]

If AVE would build engines this would be him... my respects tp you sir ✊

[@JON-mv1hu]

My head hurts but I love it and will watch agin I learned a lot from stepfather when I was younger and things are coming back thank you

[@kellylopez7004]

fuck did come where is the

[@RampantSGV]

Jafromobile Technical School... Best engine building on youtube! you are doing the world a service. keep it up.

[@dreams2memories]

Since I got those billet main caps and main girdle. I'm finally gonna be setting up the painfully long process of align boring. But it will be fun and a learning experience.

[@xXturbo86Xx]

the amount of information in every single video you make is just mindblowing. If only we could slow down the actual video and watch the whole process in normal speed.....it would be the perfect education source

[@ShuMO99]

maybe the best video I've watched this year. awesome, entertaining (gas? not me!) and educational.

[@qmawpxvecxydiwixytvieowizhehsi]

The people like you give me reason to keep fighting for the better in this life ! :D

[@BoostedBeaverGarage]

Glad to see something from you. Its nice to have some entertainment. Just got back to some internet so I have been in the dark ages for a few weeks. I expected nothing more for the Hyundai and since its getting warm out, I expect to see some good passes with the Hyundai soon. Robert

[@alexcockerill]

Thank you for another great video! I celebrated with a yell and hands in the air when I saw it was 40 minutes long! Keep up the good work, spring is almost here!!

[@Jafromobile]

I'm chomping at the bit listening to them running at the dragstrip right now. WRENCH FASTER!

[@gunawandjafar751]

NICE JOB SIR...GLAD TO SEE YOUR VIDS

[@skatedeath2186]

22min in warp speed (ludicrous speed) if you too any faster you just might go plaid...... Love the videos

[@anthonywendt5834]

Still one of my favorite videos on the tube.

[@ichangedmyusername1553]

My head is pulsing and all I can think of is that I have to clean my key with an air compressor before I put it in the ignition out of fear that dirt will work its way to the engine :/

[@tonino5113]

I follow you from Italy Your work and just perfect and the way you explain if you were my teacher in school would become mechanic I look often Roadkill hotrod thanks for having awakened my old passion

[@zx8401ztv]

Thank you, that was brilliant :-)) So many things to think about, and you have nicely balanced values. Not sure if i beleive the chair made that noise ha ha :-)) Ive never touched anything complex, just two and fourstroke motorbike engines, the very basic checks have kept me on the side of luck :-)

[@mauriciocanalez9965]

Jafromobile, I just discovered your channel!, thank you for the videos, there are very detailed! Congrats!

[@MAINTAININ227]

Excellent detail explainations, perfect work.

[@alg6343]

Just amazing .....very good job

[@sethat8e]

Can't wait to hear this beast run.

[@tangles01]

This is awesome. I'm about to have a go at blue printing my own RB25DET. Great learning tool. No it won't be my 1st rodeo, but it will be my 1st one producing over 650 Crank HP so precision is key.

[@JanMichaelSullano]

Woooaaahhh just got me saying, I need to study further before I start overhauling and replacing parts of my Hyundai kappa 1.4 MPI gas engine. I have been doing study and research on putting turbo on this engine. No worries blowing it but to do it the right way is important to me.

[@youtubasoarus]

Awesome video. Thanks for making it Jafro!

[@mithious88]

"these arn't the droids your looking for" Another awesome video. Great pace.

[@DENicholsAutoBravado]

Round about way of saying, really cool? :) I speak Star-Wars-Fan enough, I think. :)

[@DENicholsAutoBravado]

DE Nichols LOL, I hadn't seen all of the video yet for Jafro to say that :)

[@pprotory]

I bought that same torque wrench when snap-on first started offering them and instantly regretted it. The following week I bought the flip dial mechanical ones and never had a problem again. Allegedly they came out with a version 2 that didn't go through batteries like a champ but I was too skeptical to try.

[@darioandrade8558]

looks like you know what doing sir!! good video

[@vwivancc]

Wow, is excellent yout work. Regards from Mexico.

[@CellarDoorCS]

Your best work yet!

[@jackrichter6400]

I build a turbo engine like that for my cousin, he only broke it once in six years,they are strong motors. Good job

[@laohantun7404]

Very detail......good work mate.

[@BryantKieu]

Great work as always!

[@maldo72]

I have to say great tech videos keep up the good workn

[@jr3474]

This is a professional work, literally...

[@Jafromobile]

The engine or the video? :P

[@IAutoEnthusiast]

Really enjoyed your videos.

[@antegas]

Thank you very much! Jafro for your effort.

[@SynicalBeats]

Another great video. Thanks *****

[@user-tn6li9hf7f]

Christopher Bowley ههههههخههههه اخذني وياك

[@MikeBeazy]

i dont know much about the detailed internals on engine parts, but this really helped even though i drive a "murricamobile" aka a mustang

[@donjuan7671]

My script for the voiceover is 6 times longer than the whole script for the movie Pootie Tang. 6 times. Longer. Probably the best thing ive read in along time

[@danielroszak8538]

tak jest podstawom w tej pracy jest czystosc nastempnie dokladne oglendziny bloku silnika ruwniesz panewek balansu jezeli posiada wiedza przekazana w tym filmie to podstawa przy remoncie silnika jezeli tego niewiesz nie zabieraj sie za to w silnikah produkowanyh obecnie w ktutyh sa montowane filtry dpf muwie o dizlah hociasz w materiale jest silnik benzynowy to bordzo wazna jest kompresja a zwlaszcza kompresja spalania inaczej fehoding od tego zalezy kultura pracy silnika gluwny wplyw na to ma dobranie panewek wymiana panewki korbowodu nowy sfozen tlokowy co zapewnia wymagana wysokosc tloka przy ot o czym w materiale nie bylo mowy wsumie byl omawiany silnik benzynowy pozatym czystosc i jeszcze ras czystosc

[@maldo72]

As always great video.

[@MechRider89]

yay a new video from Jafro!!!!!

[@joeybuddy96]

1:01 Had this crank in the fridge leftover from the bbq cookout last weekend.

[@PHUSII]

great information here!

[@msenglish8382]

awesome video

[@aswinaswin1009]

nice video sir

[@SwPiotrek]

Great video. Thanks!

[@ahmedm9557]

really good that was very awesome

[@AutomotiveAnonymous]

Thumbs if this is done right.* * I'm not doing this for likes. This comment is for the benefit of a noob's confidence.

[@Jafromobile]

I see what you did there... Thanks, that's pretty cool! ;)

[@kingreef2160]

my head blow up watching this

[@Jafromobile]

+King Reef I just watched the whole thing again. Thank you! It is definitely intense.

[@jarpen3]

Respect for engine Master.

[@s0012823]

Awesome video, I love your attention for detail. I am curious how much difference it makes when you just build it up without paying attention to these details. But that's not the point of course, it's just great that you love your work so much.

[@Jafromobile]

+s0012823 It's the difference between knowing you can pound on it, and not knowing what it's going to do? Worst case scenario is you get an oil clearance wrong and munch the engine shortly after cranking it. This is all stuff you absolutely have to do. Now you know how. ;)

[@danfoutger]

very Amazing and impressive.

[@Engineerboy100]

Nice video thanks

[@nathanjacobs4244]

These aren't the droids your looking for,,,,,,, Lmfao, I had to pause this video to comment, laughed hard enough to have tears, Your stuff gets better n better. And im still years behind

[@mohamedhameed6172]

I like that good work

[@pierrebrown9407]

Jafro you truly are amazing bro. Your vids are my go to. I can't find the section that includes installing a new timing belt, tensioner, and or blanace shaft delete? Am I overlooking it?

[@muhammadakmal3246]

Good working

[@richardlindsay3958]

Magnificent!!!!

[@RGTGAME]

Jafro, do you have to get the rings bang on specs or aim for around the spec? if not, how much off are you allowed to be off; 0.0005? more? One of my rings gives a little drag on the feeler gauge but another it slips right in but the next size up will not without moving the ring so I guess it is in the middle, is that ok or have I taken one too far? Thanks!

[@MrPoeta69]

well done !

[@kevin-jm3qb]

you my good sir............are a saint..............now its time for you to do a 2jz-gte motor

[@denelvo]

Backfire hurts engines. Flatulence does not.

[@2076649]

Because Jafromobile told me to use mayo as a assembly lube!

[@johndangelo9630]

Excellent

[@debarra136]

That was great, thanks.

[@checkmatenate]

Very nice

[@spowyou]

Metric system RULES !!! :))

[@user-nd2ry9sk3o]

thanks. this is helpful