Ordering Parts, Short and Long Blocks, and Engine Assembly

1. Ordering Parts, Short and Long Blocks, and Engine Assembly Chapter 55

2. Objectives • Order the correct parts for an engine • Decide the best course of action for engine repair, rebuild, or replacement • Reassemble an engine in an organized manner to industry standards

3. Introduction • Before engine assembly • Look in service manual for special instructions • Have tightening specifications handy • Clean all parts thoroughly • Obtain replacement parts

4. Ordering Parts • After block has been disassembled • Inspect parts for damage and make a list parts • Part types • Factory replacement parts • Categorized as OE • Stock • Part is same as manufacturer • Aftermarket • Part sold by non-OE market • OE engine parts may be manufactured by same manufacturer as aftermarket parts

5. Engine Kits • Contain most parts to completely rebuild an engine • Costs far less than separately purchased parts • Kits for various groups of parts • Crank kit, timing chain set, overhaul kit, and master kit • Part cores • Core charge will be refunded when parts are returned • Save crankshaft woodruff key and pilot bushing

7. Determining Part Sizes • Engine size: determined in several ways • Books or programs that list casting numbers • Numbers stamped on block • Measuring cylinder bore • During inspection of parts • Watch for unusual oversized or undersized parts • Manufacturer codes indicate use of nonstandard parts • Measure all parts

8. Types of Engine Rebuilds • Custom rebuild • Customer’s engine rebuilt for use in same vehicle • Short blocks • Completely assembled rebuilt blocks purchased from machine shops • Do not include external parts • Long blocks • Cylinder heads installed on short block • Engine core • Old block assembly is returned to rebuilder

9. Selecting the Correct Replacement Engine and Warranty • Be sure replacement engine is correct • Engine parts can be different • Rebuilt engines may have short warranty • Longer guarantee means higher cost • Fuel and cooling system hoses not in excellent condition • Must be replaced • Preliminary estimate should include these things • Be certain water pump and radiator are in good condition

10. Reassembly • Important steps • Inspect and count all parts • Prepare cylinder block for reassembly • Clean block with soap and water and oil it • Clean oil galleries with rifle brush • Install oil gallery and coolant core plugs in block • On pushrod engines: install cam bearings • Chase all threads in block with a tap

11. Begin Reassembly • Important steps • Begin assembly after thorough cleaning • Lubricate all wear areas generously • Use assembly lube with grease consistency at room temperature • Install cam on a pushrod engine • Be sure it turns easily • Install sprocket and use as temporary handle to turn the cam

12. Prepare the Crankshaft for Installation • Major steps • Remove old crankshaft and install new one • Be sure woodruff key is flat in groove • Crank is in block: heat sprocket for easier installation • Install sprocket with timing mark facing outward • Be sure that the surface the rear seal rides on is clean

14. Install the Crank • Major steps • Install main bearing caps • Check bearing oil clearance • Tighten the main caps • Align the thrust bearing halves • Assemble pistons and rings • Install connecting rod bearings • Install piston and rod assembly in block • Check installation of rods and bearings

15. Install the Cylinder Heads and Install OHC Heads • Install cylinder heads • No dowels to align heads: make alignment pilots • Compare head gasket to head to see it is correct • Installing OHC heads • Number one piston at TDC • Camshaft turned in head until timing mark is properly located • Install head on block after bolt threads are cleaned on wire wheel

16. Install the Cam Drive (Pushrod Engines) • Major steps • Install chain and cam sprocket • Set cam timing properly

17. Install Valve Train Parts • Major steps • Oil and install lifters • Coat bottom of each lifter with assembly lube • Install pushrods and rocker arms • Lubricate all wear areas • Tighten bolts on rocker shaft closest to center first

18. Install the Oil Pump and Install the Timing Cover • Install oil pump • Fill pump with oil • Install pump • Make sure pickup screen properly positioned • Install timing cover • Install woodruff key and oil slinger • Install timing cover • Engine does not have timing cover aligning pins: align it by temporarily installing the damper

19. Install the Damper • Major steps • Damper installed until bottoms out against oil slinger and timing sprocket • Install large washer behind damper retaining bolt • Read instructions before installing gaskets • Special tips may be important

20. Install the Oil Pan • Oil pan installation: especially important • Replacing pan gasket much more difficult when engine is in the car • Major steps • Be sure oil pan is flat and not dented • Apply RTV silicone sealant where side rail gaskets join gaskets on front and rear of oil pan • Be sure nothing is left in the engine

22. Install the Intake Manifold, Thermostat and Water Outlet Housing • Install intake manifold and torque • According to torque specifications • Install thermostat • Temperature sensor facing into the block • Installed upside down: engine will overheat

24. Completing the Assembly • Major steps • Paint the engine before installing exhaust manifolds • Do not paint exhaust manifolds • Spin test rebuilt engines • Compression and oil pressure can be checked • Cam, rod, and main bearings can be visually checked for excessive bearing oil leakage • Pushrod engine lifter rotation can be verified

25. Install Exhaust Manifold(s) • Install exhaust manifolds after block assembly is painted • Important steps • Tighten bolts in center first Make sure dowel holds are clean • Tighten individual manifold-to-engine bolts first • Then tighten bolts where parts meet