How to check the big end of connecting rods.The subject rods are from Subaru EJ25 engines I started out with 19 rods, the 20th rod was junk from being spun so bad.Commonly the pistons are removed from any connecting rod being checked.First thing to do is clean the rod of old oil...

How to plug the crank oil galleysI have spoken out about removing the oil galleys balls in the crank.So once the balls are outSo all the crud can be removed.After you have gotten most of the crud out, spray with brake cleaner.Then use a small brush to scrub the...

Short block teardown and inspection 7bolt 4g63TI had this short block dropped off at my shop about 8 months ago as a core turn in. The story I was told was it had less than 2000 miles on it. It was shipped in from another machine shop that specializes in the 4g engine.First thing I noticed...

4G63 Block VentI have read a few threads on adding a block vent to the 4g63. I know this not a new idea, and others have had done it before. I also know that there is a kit so a block vent can be added in at the rear balance shaft timing passage. Some of the locations I have seen used I did...

A look at the 4G63 PCV system Engine internal view.I know this topic has been covered in depth over and over again. DSM Wiseman has a great write up on it from the valve cover out, and covers how the system works. If you have not read it, you need to...

Pull your balls to properly clean your crankI know this topic has been talked about some. Some say it not needed, but I disagree. The crank for a 4g63 is of the cross drilled design.This means that there is an oil galley through both the main and the rod journal with an intersecting oil...

2G 7 Bolt Oil Squirter Block offIt is common practice in a rebuild to block the oil squirters that are fed from the mains of the 2g 7 bolt blocks. This style of squirter can rob oil from the main bearings if they fail open, or become dislodged from the press fit bores they are installed in...

BSE Block Bearing FlipThis is for a BSE done at the time of the engine build. This will not be the BSE procedure used while the block is still in the car. This is not overly complicated to do, just attention for detail needs to be used.The tools needed are few, *Decent sized hammer...

BSE: Front Case PrepIt seems that some of the new guys are having a few issues doing a basic BSE. This is just one step of what needs to be done for a full BSE.This should show the basic steps needed to prep the front case for a BSE.The basics needed *Front case, cleaned *Hammer...

Head Inspection # 10I had a head sent in by a customer that just had the head rebuilt through his tuner. The machine shop that built the head did not have a full understanding of the 4g63 head. This head was built with SuperTech single springs and Kelford 272 cams. For the most part the head...

2G 7 Bolt Oil Squirter Block offIt is common practice in a rebuild to block the oil squirters that are fed from the mains of the 2g 7 bolt blocks. This style of squirter can rob oil from the main bearings if they fail open, or become dislodged from the press fit bores they are installed in...

BSE Block Bearing FlipThis is for a BSE done at the time of the engine build. This will not be the BSE procedure used while the block is still in the car. This is not overly complicated to do, just attention for detail needs to be used.The tools needed are few, *Decent sized hammer...

BSE: Front Case PrepIt seems that some of the new guys are having a few issues doing a basic BSE. This is just one step of what needs to be done for a full BSE.This should show the basic steps needed to prep the front case for a BSE.The basics needed *Front case, cleaned *Hammer...

I commonly get asked why I want to deck a block.Some look at me and think it is just to run up the machine bill. That is not it, it is because it is needed 99.999% of the time.I had to deck 4 blocks the other day, 4g63 6 bolt, 4G63 7 bolt, 4G63 and a 4GJSThe 4GJS had the lowest miles on it...

A look at the Manley stroker pistions, Part # 608005c-4I had a customer drop off a set for a build.Manley always seems to have a pretty piece in the box.The box claims that that the pistons weigh in at 296-297gOut of the box they were appox. a gram heavy 297-298g .8g to be exact...

4g63T Short Block Inspection 6 BoltA customer came in and dropped off a 6 bolt short block. He was feeling a bit “iffy” about the rebuilt short block he had just bought. It was supposed to be drop in and run ready.After a look at it in the back of the truck, we agreed it would be...

How to figure Compression RatioI have noticed very few know what their real compression ratio (CR) is. Most think since they have 9.0:1 pistons, that they have a 9.0:1 CR engine. The pistons in the engine are only one part of the formula. Several other things can affect CR, such as having...

I have to assemble a couple of stock rod 6 bolt short blocks, both .50mm or .020 over.I know the closer the weights of the parts, the smoother the engine runs.So since both short blocks are getting the same part number pistons and the same size, I can mix and match as needed.Box #1 Was...

I needed a set of stock rods for a simple no frills short block.I grab a set, press the pistons off and clean them.I weigh each rod and find a difference of 7g from low to high.I thought that was a fluke, so I grab up all the stock 6 bolt rods and press the pistons off.23 rods weight out...

In the past week I have torn apart some front cases. I would have thought by now even the newest DSM'er would have found the info on what stubby shaft to run.I know this is not a new topic to cover by any means. :banghead:STAY AWAY from the ungrooved stubby shaft!!!!This one had to be...

1G Turbo Oil Feed Port RepairI had a 1g head come in that was really messed up. At some point in time someone had tried to install a heli-coil as a repair. The heli-coil was set too deep and was just a flat out mess.This repair has to be done with the head out the car and off the...

Checking 4g63 Valve SpringsI have been saving valve springs from several cylinder heads. I decided to check the spring pressure.I tested the valve springs using a 1.560 installed height. For a valve spring to be good I wanted to see a minimum of 60lbsI checked 460 valve springs or...

I have a broken bolt in a Honda exhaust header.It is broken off about 1/8" above the flange.Just enough to get a bite on it with some vise grips.First thing I am going to do is heat it up with a torch.Make the area around the broken bolt glow.At this point , work...

Ok I need a bit of help making a decision. I figured I would ask the DSM brethren. :DFirst and foremost I am not a welder, I have an old Lincoln dog house stick welder, and the legendary Harbor freight $99 gas-less mig welder that I glue steel together with.So what I know about welding...

Manley Piston InspectionPart # 605105c-4Every thing seems to bee here. 4 Pistons 4 Ring sets 4 wrist pins Bag of locks , feels like 8The spec sheetThe weights were close out the box, and were off in the range on the front of the box. Box is listed 351g...

Broken exhaust stud repair.I had a cylinder head come to the shop, it had a bad drilled exhaust stud. Whoever tried to remove the broken stud before, did not do the best of jobs. Part of the old stud was still in the hole. Along with part of an EZ out.I took a die grinder...

This is simple enough to do.What is needed Hose clamps Screwdriver Some hose to fit the oil cooler Bucket with water Compressed air sorce thats regulated ( Leak down tester will work)Start by removing the sandwich oil cooler from the engine. Clean as needed.Attach hoses, one...

1997cc (2.0) DOHC,16v,Vin Y, 1995-99Some part numbers for1996cc (2.0) DOHC, Vin Y 1995-99 Avenger, Neon, SebringFrom the SBI Parts catalog, Block 16Valve Int 01730 1.370 Head dia Exh 01731 1.201 Head diaTakes a single round bead on the mitsu, the Chrysler takes a triple...

With oiling being critical on any engine, any improvement in the factory oiling system will be helpful.I feel this should be done on any rebuild including the most stock rebuild.On the front of the 4g63 engine there is 2 oil transfer galleys that work with the oil pump/front case. These...

I know not everyone has a machinist straight edge in with the tools they own.:aha:This is not the most accuate check But it should be close enough to help you decide if a MLS will seal or the block needs to come out and me milled flat.Tools needed 20" or longer extention, 1/2...

yes those are stock or stock replacement pistons

I did not write this, this is from CHP- Coast High Performance Website. Coast High Performance: Ford, Chevy, Stroker Kits, Short Blocks, Long Blocks, Crate EnginesForged Pistons "Forged" pistons are mechanically shaped into a piston shape. They are hammered, pressed (forged) into a mold...

I just had to take pics of this and post.What some people do to cheap out on a build.Take one Honda D16Y6 block and add a cheapskate and mix in one 4" side grinder.The HG surface of the block, Keep in mind this engine runs a factory MLS HG.Closer viewSo I get the...

I had a customer drop off a 1g 6 bolt short block, the timing belt broke and valves hit the pistons.See where the valves hit.Rotate the engine over so all 4 pistons are about the same level in the block.Now take a screwdriver, stick, paint stirrer and mark it about an inch from the...

General Knowledge*How to figure Compression Ratio*Engine Machine work explained – written by Big Woo*Delta "HKS272 Regrind" Info. – written by bastarddsmCylinder Head*4G63T Head oil port mod*Oil port mod #2 for the 4G63t*1G head flow numbers and intake designs...long – written by...

This is a fairly simple thing to do.Dial calapiers and a basic calculator and paper and pencil is what is needed.First is to measure the cans base circle. The base circle will be the smallest measurement.This was 1.181 on this camNext is the Toe measurment is next and will be the...

4G63T Block CorrectionThis block was machined at another shop, then ended up at my shop.To start with the block gasket surface was belt surfaced. I have heard of this being done, but this was the first time I have seen it in person.A longer viewThe hone job was sub par also. But...

Valve spring comparison #2 Evo VIII, Stock DSM, Manley, Brian CrowerFrom left to right· Used EVO VIII · Used Stock 4G63 · Used Manley · Used BC1100 · New BC1100The EVO springs, set of 16, tested 58-62 lbs @ 1.530Used stock 4G63 valve spring Appox. 140k miles 56lbs @ 1.530Used...

4G63 Dropped Valve Head RepairThe Subject head is a 1G 6 bolt head. This head had extensive work done to it and would cost way more to replace than repair.The head was loaded with SuperTech +1mm valves, and duel valve springs and Ti retainers.How the head looked when I received it.A...

4G63 Head Build – ModifiedIf you have not read http://www.dsmtuners.com/forums/cylinder-head-short-block/420045-how-have-4g63-head-rebuilt.htmlRead that one first, alot has been left out in this build that has been covered in that thread.Please keep in mind some machine shops can...

I came across a set of 4g63 valve springs I do not recognize.The paint stripe on it is light yellow or a cream color.I know what it is not.Not stock DSM Not HKS - has blue/green on bottom coils Not BC1100-Has thin blue stripe Not Manley-Yellow wide stripe center coils...

How to package a head for shippingWhat you will need is a stout box, appox 2 inches wider, longer, and about 4 inches taller. A roll of packing tape, and a plastic bag or tow. Tall kitchen trash bags work well. Newspaper ** Tech tip** remove any odd parts such as cam gears or...

This thread is for tech info/data only. If you do not have anything to contribute that will help others identify what camshafts they have, please do not post. If you do have helpful info, please make sure to upload your pictures to the site so they will not be lost. Posting data without...

Fel-Pro Head Gasket InfoThe Part Number 9932PT SOHCRetails for appox $53-$57The Composite Part Number is 9627PTFELPRO CYLINDER HEAD GASKET, STEEL CORE LAMINATE, SOLD INDIVIDUALLY -- 3.346 in. bore, non-lock wire; Made of high density material and superior design...

How to Measure, Mic, a PistonSupertech PN# P4-MA835-N4Factory supplied spec sheet.They ask for a bore spec 3.287/83.50 mm, This what is your recommend bore size.Tools needed for the procedure, Outside micrometers 3-4 inch,But in a pinch, venire calipers will "Get...

How to cut open an oil filter and inspect.I bought a inexpensive oil filter cutter from Ebay ($38 Shipped)It is a decent enough tool, simple solid design, with rollers.Twisted 3 times and the filter can was cut.It will leave a sharp edge on both the can and the filter...

How to Measure, Mic, a PistonSupertech PN# P4-MA835-N4Factory supplied spec sheet.They ask for a bore spec 3.287/83.50 mm, This what is your recommend bore size.Tools needed for the procedure, Outside micrometers 3-4 inch,But in a pinch, venire calipers will “Get...

Oil filter cut away Fram & WIXFram on left, Wix on rightThe Fram bypass valve, also notice the cardboard end capsSee the wix filter media mount on the right, Fram has a gasket

Head Gasket Repair How to Clean the block surface Pistons installed.This is for a composite gasket, NOT a MLS.The subject block is a 4G63, 7 boltFirst roll the crank over till all 4 pistons are at mid strokeNow find some sort of grease, I am using wheel bearing grease...

Valve spring comparison BC1100 HKS StockThe line up is (L to R) BC1100 (NIB) HKS Single appox 10k miles used Stock 2G appox 140k miles Used Kia Looked like a 4G mutant Head, ? miles UsedUsed Stock 2g spring55lbs @ 1.530Kia used spring58lbs @ 1.530HKS...