Engines: Engine Rebuilding

Introduction to engine rebuilding	Engine rebuilding introduction	Although every vehicle and engine combination is different in detail, there are fundamental similarities between all internal combustion engines. The methods used to rebuild all types of engines are also very similar.
	Engine removal preparation & safety	Raise the vehicle on jack stands or ramps in preparation to remove the engine.

Removing the engine	Topside engine disconnection	The first step when removing any type of engine is to disconnect the battery. Remember to label parts before you disconnect them. The objective of this procedure is to show you how to label, disconnect and organize topside engine components.
	Front accessories disconnection	You need to disconnect the radiator, fan shroud and other accessories and top linkages before the motor can be removed. Remember to check the sides of the engine as well. The objective of this procedure is to show you how to disconnect and remove the radiator and any accessories required to remove the engine.
	Underside engine disconnection	Before disconnecting underside connections, double check the battery is disconnected and that the engine has been raised and is secure. The objective of this procedure is to show you how to disconnect and remove underside engine connections and components.
	Remove the engine	The objective of this procedure is to show you how to remove the engine from the vehicle body. Take your time when raising the motor, checking carefully to make sure all components are disconnected.

Engine disassembly	Remove centerbolt & flywheel	The objective of this procedure is to show you how to remove the centerbolt and flywheel and mount the engine in a stand. Start with the centerbolt remembering to use only high tensile grade bolts.
	Drain engine fluids	When draining fluids use separate containers to drain oil and coolant. The objective of this procedure is to show you how to drain engine fluids and remove oil filter.
	Remove front peripherals	Remove belts, accessories and pumps, remembering to make notes and diagrams as you proceed it is important to stay organized. The objective of this procedure is to show you how to remove belts, accessories, water and fuel pumps.
	Remove side & top peripherals	The objective of this procedure is to show you how to remove engine side and top peripherals. Peripherals include exhaust manifold, spark plugs and distributor, intake manifold and valve covers and oil pressure gauge.
	Disassemble valve train	The objective of this procedure is to show you how to disassemble and remove the valve train. Use an organizer tray to ensure that everything goes back into the exact position that it came from.
	Remove cylinder heads	The objective of this procedure is to show you how to remove the cylinder heads. Before removing cylinder heads, mark the heads so you know which head goes on which side of the block.
	Remove oil pan & timing set	The objective of this procedure is to show you how to remove the oil pan and timing set. Remove the oil pan, balancer, timing cover and timing set, checking for stretch on the timing chain.
	Disassemble block underside	The objective of this procedure is to show you how to disassemble the underside of the block. Drain the block and remove the oil pump and tray. Look out for any indications of engine failure.
	Disassemble pistons	Pistons and their associated parts are a matched set and must be reassembled together as a matched set. Mark and organize all parts. The objective of this procedure is to show you how to disassemble the pistons.
	Remove crankshaft	The objective of this procedure is to show you how to remove the crankshaft and bearings. Once bearings are removed examine for reusability.
	Remove camshaft	The objective of this procedure is to show you how to remove the camshaft and lifters. Make sure all the lifters are pushed out of the way of the camshaft before attempting removal.
	Remove plugs	There are many types of engine plugs, including: oil gallery plugs, water jacket freeze plugs & drain plugs. The objective of this procedure is to show you how to remove all engine water jacket and oil gallery plugs and camshaft bearings.
	Remove valve assembly	The objective of this procedure is to show you how to remove all head components. Place all the valves from the heads in their proper place in an organizer tray with all the other components of the valve train.

Engine machining	Clean & degrease engine	The various specialized equipment and tools used in this process are not readily available in most general automotive workshops, and for some or all of these you may need to use a professional machine shop. The objective of this procedure is to show you how to clean and degrease the engine.
	Inspect & measure engine	The objective of this procedure is to show you how to inspect and measure engine components. Check for cracks and wear as well as measure components to ensure they are suitable for reuse.
	Machine diagnosis	The objective of this procedure is to show you how to identify reasons for machining components. When the inspections and measurements are completed, you will be able to diagnose what parts need machining and which need replacing.
	Machine cylinder block	The machining process removes material and this causes heat to build up in the component. Always allow breaks in the machining process so that components can cool. The objective of this procedure is to show you how to machine the cylinder block to operational condition.
	Machine cylinder heads	The objective of this procedure is to show you how to machine cylinder heads to operational condition. In the machining process its important to remove the least amount of material possible.
	Machine connecting rods	The objective of this procedure is to show you how to machine connecting rods to operational condition. Once you have ground the rod ends and installed new rod bolts you must realign the connecting rod big ends back to a perfect circle.
	Clean pistons and fit new pins	Rod ends need to be heated to allow the tight fitting pin to be pushed home. This process needs to occur quickly to avoid the pin getting stuck part way. The objective of this procedure is to show you how to clean pistons and fit new pins.
	Hone cylinders	The honing process does two things: First, it enlarges the cylinder bore to the exact size that is needed to give the specified amount of clearance between the piston and the cylinder wall. Second, it leaves a fine crosshatch pattern of light scratches on the walls of the cylinder that are necessary to retain microscopic beads of oil. The objective of this procedure is to show you how to hone the cylinders to operational condition.
	Install piston rings	The gap in the ring must be at a precise specification when it is installed on the piston and inserted into the bore. The objective of this procedure is to show you how to install the piston rings.

Engine pre-assembly	Pre-assembly introduction	It is very important to perform a temporary test build up of the rotating assembly. The objective of this procedure is to show you how to undertake final check of components for pre-assembly.
	Test install camshaft	The objective of this procedure is to show you how to test install the camshaft. When you slide the camshaft in, take your time and be really careful.
	Test install crankshaft	The objective of this procedure is to show you how to test install the crankshaft. Before you begin double check the new parts labels to make sure they are the correct type and size.
	Test install timing set	The objective of this procedure is to show you how to install the small timing gear. Align the crank and camshaft through the timing marks. If they are hard to see, paint them.
	Test install pistons	The objective of this procedure is to show you how to test install the pistons. The objective of this procedure is to show you how to test install the pistons. A pre-assembly check of the piston bearing clearance is quicker if you don't install the piston rings.
	Test install oil pump	For every rebuild it's a good idea to get a brand new oil pump. The objective of this procedure is to show you how to test install the oil pump and pick up tube.
	Piston to valve clearance check	If the camshaft has been changed in the rebuild its essential to check the piston to valve clearance. The objective of this procedure is to show you how to check piston to valve clearance.
	Long-block build-up	The objective of this procedure is to show you how to build-up the long block. Install heads, intake manifold, distributor and covers. If everything fits, disassemble the engine again.
	Paint the engine	The objective of this procedure is to show you how to paint the engine. Ensure all holes are plugged or masked to prevent paint from getting into the engine.

Engine final assembly	Fit engine plugs	The objective of this procedure is to show you how to fit engine plugs. When fitting plugs, work systematically around the engine make sure you don’t miss any. Double check your notes and the manual to make sure that all the plugs have been installed.
	Install camshaft	The objective of this procedure is to show you how to install the camshaft. Lubricate the camshaft as you insert it and wear gloves that protect your hands.
	Install crankshaft	The objective of this procedure is to show you how to install the crankshaft. The first step is to clean the block, bearings and crankshaft in preparation for the installation.
	Install timing set	The objective of this procedure is to show you how to install the timing set. Always ensure the timing marks are lined up and double check your alignment when you have one or two bolts in, before all bolts are in.
	Fit piston rings	Clean the cylinders and wipe a thin even film over the cylinder before installing the piston rings. The objective of this procedure is to show you how to fit piston rings.
	Install pistons	The objective of this procedure is to show you how to install the pistons. Once pistons have been in stalled, use a torque wrench to tighten all bolts and nuts. After you have torqued all of the rod journals, leave the wrench on the final setting and go through every bolt once more.
	Install timing cover	The objective of this procedure is to show you how to install the timing cover. Add timing cover seal and gasket before putting on the cover and tightening the bolts to the correct torque setting.
	Install rear main seal	If you have a one-piece main seal that is not already installed, fit the rear main seal mount past the engine stand adapter and seal and bolt it in place. The objective of this procedure is to show you how to install the rear main seal.
	Install oil pump & pan	The objective of this procedure is to show you how to install the oil pump and pan. With almost all oil pan gaskets, it's a good idea to let the pan sit for a minute after you torque the final setting. Then go back through all the bolts again.
	Assemble heads	The objective of this procedure is to show you how to assemble the heads. Be sure to keep the valves and the springs and retainers in the right order, and double check to make sure that the valves are going into the correct head.
	Install heads	The objective of this procedure is to show you how to install the heads onto the block. Cylinder heads require that you torque the bolts in a certain sequence. If your engine has it's own particular pattern, follow the instructions in the repair manual.
	Install valve train	The objective of this procedure is to show you how to install the valve train. Ensure all parts have been lubricated prior to assembly. In almost every rebuild the lifters are replaced and can go in any order in the block.
	Adjust valve lash	It is important to adjust to zero lash so that all slack is taken out. The objective of this procedure is to show you how to adjust the valve lash. Remember to follow the firing order when adjusting the valve lash.
	Install intake manifold	The objective of this procedure is to show you how to install the intake manifold. The intake bolts usually have a tightening sequence similar to the heads, but the sequence usually starts with the middle bolts near the plenum.
	Install engine externals	The objective of this procedure is to show you how to install engine external components. Engine externals components include: harmonic balancer, fuel pump, water pump, thermostat, and exhaust manifold.
	Pre-oil engine	The objective of this procedure is to show you how to pre-oil the engine. Use an engine oil recommended in the repair manual. Don't use an oil with a detergent additive. This is not ideal for breaking in bearings and seating the new piston rings.
	Install distributor	The objective of this procedure is to show you how to install the distributor. The distributor must engage with the oil pump drive shaft.
	Assemble accessories	The objective of this procedure is to show you how to assemble the accessories to the engine. Install accessories, flexplate, flywheel and clutch assembly and tighten centerbolt.

Engine re-installing	Hoist & reconnect the engine	The objective of this procedure is to show you how to hoist and reconnect the engine. Check the engine bay before re-installing the engine and securing it to the engine mounts.
	Connect engine peripherals	The objective of this procedure is to show you how to connect engine peripherals. Refer to your notes to connect underside, front and topside accessories.

Engine start-up	Pre-start engine check	An pre-start engine check includes checking all hoses and lines, filling the radiator, checking oil level, fuel systems battery and ignition system and ignition wiring. The objective of this procedure is to show you how to conduct the pre-start engine check.
	Camshaft break-in	If you have a new camshaft, the break-in procedure is critical. The objective of this procedure is to show you how to conduct camshaft break in procedure. Run the engine for 20 minutes, top up the radiator and check for leaks.
	Engine timing adjustment	The objective of this procedure is to show you how to adjust the engine timing. Find the timing recommendation for your engine in the Repair Manual. The Repair Manual should also give you details on what type of timing marks you have on your engine.

Topic group	Topic	Summary