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4g54 Rebuild #1077867 04/29/15 09:18 PM
Joined: Apr 2015
Posts: 13
BSRJIRONMAN Offline OP
Need a Spot
Hey all,

new to the forums. I've got an '87 Montero. Had it for about a month. Long story short, I didn't do a compression test on it before buying it, I just assumed the 2.6 sounded "lopey". After trying to track down and fix some oil leaks, I discovered high crank case pressures (high velocity air coming out of the oil cap, and dipstick tube). Finally did a compression test, results as follows:
1=70psi
2=160psi
3=160psi
4=175psi

Oil in cylinder resulted in pressure increase to 150psi (cylinder 1) soo...rebuild is in order.

Anyway, looking for any tips and known issues to look for in these 2.6 engines, as I will be breaking it apart myself. I'm kicking around the idea of just doing a re-ring and honing it myself, but I guess I'll just wait to see what condition the cylinder wall is in. Anyone with experience doing just new rings?


How would I describe myself? Three words: Hard-working, alpha male, jackhammer. Merciless...insatiable...
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Re: 4g54 Rebuild [Re: BSRJIRONMAN] #1077868 04/30/15 02:04 AM
Joined: Feb 2001
Posts: 1,979
JAVYPRO Offline
Body Damage is Cool
Get the MFS or is it MSF or FMS or SMF???? Bah!!! the manual you can download from http://www.mitsubishilinks.com/

This engine is so simple so normal simple tools and torque wrench will do.

Others will chip in on anything that you might have a question on.

Javy


88 red Montero with the Dakar Special Edition decals, 438,000 miles (As of 7/23/2012) some occational blue puffing but still strong and counting!!! I am going ppsshhh (turbo), Stay tuned =) ...
Re: 4g54 Rebuild [Re: JAVYPRO] #1077869 05/01/15 10:46 PM
Joined: Dec 2008
Posts: 655
zarktheshark Offline
Rock Warrior
*****
I'm in a similar situation where it was rebuild the 2.6L or do a motor swap. I had it rebuilt once, but it blew after 30k and it was not because of abuse. This time I'm doing the swap. I have a new GM TB efi tuned for the 2.6 if interested...I'm not going to need it anymore <img src="/forums/images/graemlins/lol.gif" alt="" />
As for things to look for and possibly upgrade, look at the head. Most go with a Clearwater head that eliminates the jet valves as that is a weak point if ever the engine gets a little hot. Outside of that, don't use cheap parts and do not reuse the head bolts\studs. Probably best to spend a little more and use OEM stuff.


'88 Raider. 2.6L dead...2.4L swap in progress, AT, 33's, 2 bouncy seat,AC, CC, 2.25 exh, 2" Tbar, 2" BL, rear DB, rear LSD,4.90's, SW hubs,gen2 uca's, KYB shocks, snorkel, elec fan, MSD.

'99 chev k3500 crewcab
'15 Subaru XV
'94 YJ
'86 Fiero GT
Re: 4g54 Rebuild [Re: BSRJIRONMAN] #1077870 05/02/15 10:12 PM
Joined: Jan 2014
Posts: 295
M
Malykaii Offline
Mudrunner
Here's my story, maybe some of it may be useful. I was swapping from g54b na to turbo only to realize the donor turbo engine was shot. So I built the na block to turbo spec. All I had do was pull the pistons and swap/hone. Upon removal I see one of my rod bearings was destroyed and could have spun. Since I needed to now have the rods inspected and ground back to round, I decided to order new pistons and have the machine shop press them on instead of diy press on the used ones. In your case since your not swapings, check your rods for roundness and bearings for signs of damage. Get new rings and get new main/rod bearings. Rockauto closeout is your friend here. ($3 sealed power rod bearings for me) Sealed power and clevite are good suppliers. You can, like me, do this rebuild without even dropping the trans or removing the engine, just roll the bearings in. Harbor freight hone and ring compressor do a great job here.

Next up, do all the timing components. Cloyes does well. Check oil pump for clearances as they usually are fine. A new,one is pricey, so if yours is shot, nothing wrong with a good used one. Pull and check your balance shaft bearings. Mine were chewed up so I eliminated the balance shafts. Your discussion here. I got the cheapest,master gasket set, dnj?, as paper and rubber are all pretty similar. Threw out the head gasket and got a fel pro, as here it counts. Bam, with machine shop,timing parts, pistons and all I was out $300 with my time. You could do the bottom end for half if your pistons and rods are fine.

I didn't touch the head as the previous owner put in a new one a few years back. In your case, check to make sure its flat, uncracked and not warped. That's the weak point of these heads. Once they warp the around of money you can drop fixing it up and do I,g a valve job outweighs just getting a new Clearwater. If yours miraculously checks out, a quick $50 mill at the machine shop, a diy valve lap with some rockauto closeout valves, a jet valve elimination kit, and fresh headbolts, done for $100.


88 Montero, StarQuest turbo, Kormex 5speed +tuff-pan w/phoenix f. stage2 clutch, 4in lift+33' tires, 4.875 lsd, short-throw shifter, Aisin hubs, SR big brakes, gen2 uca's, elantra alt, and so much more... 16g turbo w/hardpipes + 4.90 locking disk-brake axle soon (maybe lsd or aussie front??)
Re: 4g54 Rebuild [Re: Malykaii] #1077871 05/02/15 10:19 PM
Joined: Jan 2014
Posts: 295
M
Malykaii Offline
Mudrunner
Normally I like to make clear and coherent posts. Right now I'm lazy, and it's to much to type up well... So yeah, typos and stream of conscience writing. I didn't even proof read. Good luck. Oh,and do the head bolt retorque procedure correctly. Previous owner of mine didnt, and fail enaured for me.


88 Montero, StarQuest turbo, Kormex 5speed +tuff-pan w/phoenix f. stage2 clutch, 4in lift+33' tires, 4.875 lsd, short-throw shifter, Aisin hubs, SR big brakes, gen2 uca's, elantra alt, and so much more... 16g turbo w/hardpipes + 4.90 locking disk-brake axle soon (maybe lsd or aussie front??)
Re: 4g54 Rebuild [Re: Malykaii] #1077872 05/04/15 04:39 PM
Joined: Apr 2015
Posts: 13
BSRJIRONMAN Offline OP
Need a Spot
Thanks for the replies!

The owner replaced the head a couple years ago, but I'm not sure if they eliminated the jet valves or not. Way to identify without removing it?

Also, regarding the balance shaft, What are the benefits to eliminating? Less failure points? Are these prone to issues?


How would I describe myself? Three words: Hard-working, alpha male, jackhammer. Merciless...insatiable...
Re: 4g54 Rebuild [Re: BSRJIRONMAN] #1077873 05/04/15 04:47 PM
Joined: Mar 2006
Posts: 422
heathdogg Offline
Mudrunner
Pull the valve cover and look. On the intake side, near the rocker arm, It will have a big valve spring and a little valve spring if it has the jet valve. I'm at the same point myself. put a crank and rod in my 2.6 or go get a wide block 2.4 from the u-pick-it here.


Blacktero: 90 Montero Lwb V6 RS Model. 16" Toyota Alloy Rims, Dual Bouncy's; Gen II Front Rotors & Calipers; Rear LSD

Sraider: 87 Raider 2.6 base. Work yet to be done.
Re: 4g54 Rebuild [Re: BSRJIRONMAN] #1077874 05/05/15 03:42 AM
Joined: Jun 2002
Posts: 6,199
JohnnyBfromPeoria Offline
Trail Leader
*****
IronMan, the balance shafts were there for a reason. The technology was licensed by other manufacturers, including Porsche...for a reason. Some will say they cannot tell the difference when they are eliminated, but there will be a balance problem that is inherent with a four cylinder engine. I'd always choose to keep them.

Heath, while the 2.4 is a great engine, keep in mind that it's not always as easy as it seems to swap one in. I've never fully integrated mine into my '86 Montero, and I wish I had just pulled the 2.6 and sealed it up and left it alone. Seriously. Even though that truck had the early 3-speed auto, at least it was a complete running vehicle, while it is not as it sits (and sits) now. The truck has been in the east valley at LordTrunk's house for a couple of months now and it still has a list of things to be done to it. Not the least of which, the a/c compressor for the Montero does NOT bolt up to the 2.4, so that whole system has to be grafted; an expensive and extensive conversion that also seems sort of essential here in Phoenix.

John B.


'87 Raider 2.6 Turbo Auto, Under Construction
'95 Montero SR, 35x12.5/15 BFG M/T KM-2's, Rock sliders, Qtr panel chop, gas tank lift, 2" BL, Aisins
'83 Dodge Power Ram, 31x10.5 on SR wheels, lifted a touch
'04 Cadillac XLR
'03 Kawasaki ZRX1200R
Re: 4g54 Rebuild [Re: JohnnyBfromPeoria] #1077875 05/05/15 04:28 PM
Joined: Jan 2014
Posts: 295
M
Malykaii Offline
Mudrunner
I'm not going to exactly answer the pros and cons of balance shafts or jet valves. A quick Google will get you hundreds of threads on the topic between here and starquestclub alone.

Its a case by case choice. I deleted the shafts as I was doing a supper budget rebuild all without pulling the engine. I found my bearings were in bad shape. Changing them would add expenses, and you can't do it without pulling the engine. Hence my choice. All I'm saying is at the very least pull your shafts out and inspect.

Jet valves are rebuildable and even for sale new. Some guy's like them. Me, budget build. Hence the cheaper option.


88 Montero, StarQuest turbo, Kormex 5speed +tuff-pan w/phoenix f. stage2 clutch, 4in lift+33' tires, 4.875 lsd, short-throw shifter, Aisin hubs, SR big brakes, gen2 uca's, elantra alt, and so much more... 16g turbo w/hardpipes + 4.90 locking disk-brake axle soon (maybe lsd or aussie front??)
Re: 4g54 Rebuild [Re: JohnnyBfromPeoria] #1077876 05/05/15 09:06 PM
Joined: Mar 2006
Posts: 422
heathdogg Offline
Mudrunner
My a/c is 2x65. 2 windows at 65. <img src="/forums/images/graemlins/smile.gif" alt="" /> I've gotta do a crank and at least a rod. Plus side of the 2.4 is fuel injection. And if they close the woods for woodcutting again this summer, lots of free time for me on the weekends.


Blacktero: 90 Montero Lwb V6 RS Model. 16" Toyota Alloy Rims, Dual Bouncy's; Gen II Front Rotors & Calipers; Rear LSD

Sraider: 87 Raider 2.6 base. Work yet to be done.
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