I forget stuff, so I'm making a detailed "step-by-step" list of all the
things I need to do for this rebuild, in order, and grouping them in related
sections. This is all being done in the hope that I manage to not have to make
repeat trips to the machine shop, the sandblast cabinet, and that this engine is
what I want it to be when I get it done. There's way too many things to keep
track of in your head for novice engine builders like myself.
| Item |
Who |
| |
| Take short block to machine shop, have
initial/prep work done, order parts |
| Verify suitability for rebuild, overbore and crank size |
Machine shop |
| Clean block, crankshaft, connecting rods, oil pan, and
front cover |
Machine shop |
| Press out old cam bearings |
Machine shop |
| Press pistons off old rods |
Machine shop |
| Order parts based on info from machine shop |
Me |
| |
| Bring short block home and modify parts
as needed |
| Clean up casting flash in lifter valley and bottom end |
Me |
| Remove machining bosses along the side of the block |
Me |
| Match up main bearing oil feed holes to bearings (use
old bearings as a template for hole enlargement) |
Me |
| Enlarge main oil feed passage to 7/16" - oil
pressure sender to just short of front camshaft bearing surface
(requires 12" long drill bit) |
Me |
| Enlarge main oil suction passage to 9/16" - front
cover to pickup tube connection + pickup tube entrance to block (requires
12" long drill bit) |
Me |
| Polish rod beam sides |
Me |
| Remove all sharp edges from piston tops |
Me |
| |
| Take short block to machine shop
w/pistons and camshaft bearings for machine work |
| Bore cylinders .060" over, hone to final piston size |
Machine shop |
| Clean block, pistons, pins, |
Machine shop |
| Press in new cam bearings |
Machine shop |
| Turn crank .020"/.020" under |
Machine shop |
| Press new pistons onto rods |
Machine shop |
| Balance rotating assembly |
Machine shop |
| Install freeze plugs and oil gallery plugs in block |
Machine shop |
| Repair eroded areas on front cover |
Machine shop |
| |
| Modify front cover and oil pump |
| Drill 1/8" hole in oil pump idler gear |
Me |
| Install cam thrust bumper in timing cover |
Me |
| Oil pump cover oil passage cleanup and
enlarging |
Me |
| Oil pump booster plate oil passage cleanup and
enlarging |
Me |
| Front cover oil passage cleanup and
enlarging |
Me |
| |
| Bring engine home and start assembly |
| Clean engine thoroughly |
Me |
| Oil all machined engine surfaces |
Me |
| Paint engine, oil pan, timing cover, and water pump |
Me |
| Install crankshaft into block and check clearances |
Me |
| Install camshaft into block - lube thoroughly |
Me |
| Install timing chain set and set cam timing |
Me |
| Install rings onto pistons |
Me |
| Install piston and rod assemblies into block and check
clearances |
Me |
| Install oil pan onto block |
Me |
| Install front cover assembly onto block |
Me |
| Install water pump onto front cover |
Me |
| |
| Other tasks |
| Clean and disassemble heads |
Andy |
| De-burr combustion chambers |
Me/Andy |
| Rebuild heads and rocker assemblies |
Andy |
| Paint heads |
Me |
| Sandblast intake manifold, pulleys, and all front
accessory brackets |
Me (w/Andy's cabinet) |
| Paint intake manifold |
Me |
| Paint pulleys and front accessory brackets |
Me |
| |
| Final Assembly |
| Install heads onto block |
Me |
| Install lifters into block |
Me |
| Install pushrods into engine |
Me |
| Install rocker assemblies onto heads |
Me |
| Install intake manifold onto engine |
Me |
| Install thermostat and housing onto intake manifold |
Me |
| Install thermostat bypass hose |
Me |
| Add oil to engine |
Me |
| Pre-oil engine using special tool - verify oil pressure
is present and that there are no leaks |
Me |
| Install valve covers |
Me |
| Temporarily install distributor |
Me |
| Install exhaust manifolds |
Me |
| Install engine mounts |
Me |
| Install all accessory drive brackets |
Me |
| Install crankshaft and water pump pulleys |
Me |
| Install starter |
Me |
| |
| Installation |
| Install lifting plate on intake |
Me |
| Lift engine off of stand |
Me |
| Install flex plate onto engine |
Me |
| Verify starter gear clearances |
Me |
| Mount transmission to engine |
Me |
| Install engine and transmission into car |
Me |
| Connect transmission cooler lines to radiator |
Me |
| Remove lifting plate on intake |
Me |
| Install carb and connect all vacuum lines |
Me |
| Hook up throttle linkage and return springs |
Me |
| Hook up radiator and heater hoses |
Me |
| Fill radiator with coolant, check for leaks |
Me |
| Mount power steering pump to engine |
Me |
| Mount AC compressor to engine |
Me |
| Hook up all engine wiring |
Me |
| Hook up fuel lines to fuel pump and to carb |
Me |
| Hook up engine ground cable |
Me |
| Hook up starter cable to solenoid |
Me |
| Connect battery |
Me |
| Remove distributor |
Me |
| Pre-oil engine again and verify oil pressure |
Me |
| Re-install distributor |
Me |
| Fire engine, bring to 2000-2500RPM and hold there for
initial cam break-in period of ~20 minutes |
Me |
| Shut down engine, let cool completely |
Me |
| Proceed with initial driving break-in procedure |
Me |
