Ok guys... so i test fitted the 4g63 today.
Which is good

However. The bonnet wont close...... 0.o.!!!!!

Using the front and rear engine mounts from the cordias old motor bolted to the 4g63.

Now heres the funny bit, the top passenger side mount i havent even made yet, therfore its not attached, and under full wieght on the other 3 mounts (front/rear bottom engine mounts, and gearbox mount).
And yes the bonnet wont close by about 15mm. ish...

@Bitza ??

Also one other thing my cordias old 4g37 is a 5 bolt crank... the 4g63 is a 6 bolt???? 0.o.. and the 4g63 flywheel wont fit under the cordia's oroginal gearbox.. will make mesurements soon and try to find one to suit, but anyone know what my problem here is?? what have you guys done about this?

Damien, as your engine is free sitting what mounts have you used?

Original ATMO or Cordia turbo ones?

Your rear gearbox mount may be holding the engine "up" due to it's length.....is it the same as the turbo version?

With your flywheel, grab a cordia turbo one (62) and your problem will dissapear.

ok heres the run down.

Mnts used
Front bottom = Stock 4g37 Bolted to the 4g63 block
Rear bottom = Stock 4g37 Bolted to the 4g63 block
Gearbox mount = The orignal one that was holding the gearbox in before. I have no idea if this is the same as the Turbo Cordia one. I've never actually worked on a cordia turbo. Both mine are GSL's

Should i maybe try force the motor downward on the passengers side by jacking up the gearbox side?
Would be on a bit of an angle if i did that though i would assume.. but maybe i'll give that a try tomrow afternoon.

Currently I have the old 4g37 gearbox attached to the 4g63 but without a flywheel/clutch.
Due to the 4g63 one that was for a SONATA is bit bigger then the 4g37 clutch/flywheel. SO i couldnt fit the gearbox over.
And as said before the 4g37 is 5 bolt not 6 bolt so couldnt use that.

So the cordia turbo flywheels are same diametre then as the GSL flywheel?

I'll take some mesurmeents of the flywheel if you would like?

Wouldnt have any extra parts from a GSR taking up space you'd want to sell hey andrew? i'll pay you dearly of course.

Thanks for your help bud

p.s. also i remember ages ago you mentioning ages the DOHC motor should have a lean to the front. Did you mean lean to front of hte car? or front of the engine, e.g. (passengers side of car)

Your gearbox is a KM162 (5 speed)?

There is a difference between the GSL and GSR in clutch size........GSL 200MM, GSR 215MM.........take some more pics of the mounts to help me understand.

ok!

So!

Ignore my posts about hte motor sitting high. Out of frustration, after i ate some food, and cleared my head,
I went back up to the shed to take a quick gander.
I didnt realize but it wasnt properly seated, as there was a pully that wasnt clearning the chasis rail, so i thought it must have had to sit above it.
Swapping it for a cordia one which is ressesed, made it clear, and then i realized the motor actually sits further down, and bam it snapped into position after a very good shaking around.! Sorry for wasting your time there... i was just having a mind meltdown after 10 straight hours working on it lol!!

However. Still have the flywheel issue.

Yes I just checked, its a KM162 5speed.
I took some mesurements for you. Look at the attached picture.

One on left is the 4g63 (Sonata) Flywheel, its too big, and the gearbox doesnt clear it.
however obviously the Sonata flywheel/clutch is even bigger then a GSR one. So if the cluth on a GSR is 10mm smaller then the sonata one, and 10mm larger then the old 4g37 one. How big is a GSR flywheel?
So should a 215mm GSR clutch and 6 bolt flywheel fit under a KM162? if so. AWSOME i'll just have to hunt me down a flywheel off a GSR if so.

Ok...

Progress.

So i ended up making some inquiries to a supplier.

turns out the 6 bolt 4g62 GSR flywheel is 262mm, and inc teeth its 270mm. So this should be fine.

I can get a Clutch Industries,
lightweight alloy flywheel for $250.
and clutch kit with the thrust bearing for $185.

Sound like the way to go? They are out of stock on the steel flywheels. (which i assume are cheaper) Anyone see any issues with getting an alloy one?

Basically Damien the KM162 is basically the same as the KM164 but it's cable operated not hydraulic.........I was just about to say the flywheel is 270mm.........with a 215mm clutch that should be fine and bolt up sweet.

Get a steel flywheel........alloy just doesn't sound right as it's a "softer" material......even though it has a hardened coating.

A lighter flywheel will allow the engine to rev cleanly over the limit, but won't have the engine braking (Deceleration) of a steel one.

If you want a little "quicker" acceleration, lighten the steel one.........have had no trouble with mine.

Awsome! thanks mate.

Ok i'll get a price for a steel one then

This afternoons progress was productive.
Allot of grinding and welding.

have gotton the top mount 'tack welded' together.
So will hopfully finish off the welds and grind it all down flush on wed afternoon.

heres some pics.

Doing well Damien.......keep up the good work.

I recon i have 4g62 flywheels in the shed, infact have a few gear boxes and engines
if you want them as well as other bits and pieces if you want them Damien

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Really, sweet!
What would you want $$ wise for one of the GSR flywheels? saves me buying new i guess. I'll just buy a new clutch in that case .
I might be able to come grab the flywheel off you on the weekend if your gonna be free at all.


Also might be interested in one of the gearbox's for my 84 AA. Its gearbox is dying a slow death lol.

Mate i will check tomorrow to be sure, if i have one there its yours
no $$ required.
It's been over 2.5 years since i had the cordia so better you using it
than decaying in my shed.

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Love the generousity there Geoff.

Yes have a gsr 4g62 flywheel, still bolted to a 4g63.
This weekend should be fine, pm'd you my details



Thanks, someone may aswell get the use of it if they need it.
would still like to get another cordia but cant see that happening anytime soon

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Wow that is awesome mate Much appreciated!

I would feel bad taking for free though, so I'd like to get your somthing
What do you drink?

Cheers

Beer , almost any type... only fussy when i'm buying

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One step closer to the end...........
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Got a bit done this afternoon.

Pulled the motor back out and stripped the wiring harness out. Also started sandblasting a few old welds and some spots ready for seam sealer.
next gotta weld in mounts for my alloy radiator.

Then will start sanding the whole bay for paint soon hopfully.


Also anyone know what the hell that canister in one of the pics attached is????? lol...

Yep........that's your evaporative emission from the fuel tank...........it's an ADR requirement so I would put it back.

haha rightio.
So what do i do with the A/C and Carb pipes?

Seeing as i will now be running MPI should the Carb pipe go to intake before the Throttlebody? (or after?)
whats A/C mean?