How to rebuild an engine

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==Requirements==
 
==Requirements==
  
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You will need a basic set of hand tools, such as a good variety of boxed end wrenches, ratchet and socket set, screwdriver set, and a gasket scraper. This basic set of tools will get you through the majority of the disassembly steps.
 
You will need a basic set of hand tools, such as a good variety of boxed end wrenches, ratchet and socket set, screwdriver set, and a gasket scraper. This basic set of tools will get you through the majority of the disassembly steps.
  
You will need a few special tools when it comes time to build or reassemble the engine. A good torque wrench, [http://www.plastigaugeusa.com Plastigauge], and a cam bearing installing tool (or have the machine shop install the cam bearings). Also, you may need a ridge reamer, a ring groove cleaner (a piece of a broken ring can be carefully used for this), a ring expander, a ring trimmer, a ring compressor, and a good cylinder hone. If cylinder head work is going to be done, a spring compressor will be needed.
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You will need a few special tools when it comes time to build or reassemble the engine. A good torque wrench and a cam bearing installing tool (or have the machine shop install the cam bearings). Also, you may need a ridge reamer, a ring groove cleaner (a piece of a broken ring can be carefully used for this), a ring expander, a ring trimmer, a ring compressor, and a good cylinder hone. If cylinder head work is going to be done, a spring compressor will be needed.
  
 
Depending on how in-depth and involved you want to get with your rebuild(s) and how many engines you think you are going to rebuild, you may want to acquire some additional measuring equipment. Items such as a set of outside micrometers, an inside micrometer, vernier, dial or digital calipers and maybe a dial bore gauge can let you know precisely what your sizes are. A "snap gauge" set can be used for spring installed height, bore diameter, etc. Think of these tools as indispensable if you are planning to blueprint your engine or if this is going to become a routine thing. You will also need a decent engine stand. It will make your build easier to support the engine, keeping it from the ground, and also helps in tearing the engine down and keeping the engine clean at assembly time. An engine hoist is also a good addition if you plan on pulling and installing many engines.
 
Depending on how in-depth and involved you want to get with your rebuild(s) and how many engines you think you are going to rebuild, you may want to acquire some additional measuring equipment. Items such as a set of outside micrometers, an inside micrometer, vernier, dial or digital calipers and maybe a dial bore gauge can let you know precisely what your sizes are. A "snap gauge" set can be used for spring installed height, bore diameter, etc. Think of these tools as indispensable if you are planning to blueprint your engine or if this is going to become a routine thing. You will also need a decent engine stand. It will make your build easier to support the engine, keeping it from the ground, and also helps in tearing the engine down and keeping the engine clean at assembly time. An engine hoist is also a good addition if you plan on pulling and installing many engines.
 
===Selecting tools===
 
For each tool needed to rebuild an engine, we'll need to know:
 
*Approximately how much do the tools cost?
 
 
*Is it better to buy a cheap version of this tool, or should you spend money to buy a high-quality version of this tool?
 
 
If you're starting a "project" or work on cars often it would be wise to spend the extra money on higher quality tools. Cornwell, SK, Starrett, Craftsman, MAC and Snap-On are commonly known to be the "best tools". Snap-On is a little better quality, but cost considerably more and can sometimes be a pain in the butt to exchange your broken tool since you would have to chase down one of their trucks. Craftsman is a good brand of tool too, and can be bought at almost any Sears department store as well as many K Mart stores since they connected with Sears ca. 2012. Look on the package when you buy hand tools; most have a lifetime warranty on them, even the cheapest ones.
 
 
For the most part your basic hand tools and a few impact tools will do the majority of the work but as listed there are several specialty tools to consider purchasing or renting:
 
 
*torque wrench
 
*ring compressor (ring expander is a huge plus)
 
*dial caliper or vernier caliper
 
*degree wheel (explained below)
 
*dial indicator and dial bore gauge
 
 
Eventually it will come time to install your camshaft as well. If you are planning on doing this yourself, you will need a degree wheel. You can buy these alone, or in comprehensive kits from somewhere like Jegs, Summit, or maybe even a local shop. They go for around $200. Just the wheels themselves can be purchased for as low as $10.00. You will also need a dial indicator, as well as a magnetic stand for it. These can also be purchased at Jegs, Summit or even your local Harbor Freight store. The larger the diameter of the degree wheel, the easier it is to be accurate.
 
  
 
===Purchasing tools===
 
===Purchasing tools===
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A lot of rodders prefer their horsepower coming from big displacement high output engines. If this sounds like you, your engine rebuild might cost considerably more than a stock engine rebuild/hop-up. The most popular route for wild engines include the big three domestic car producers: GM, Ford, and MOPAR.  
 
A lot of rodders prefer their horsepower coming from big displacement high output engines. If this sounds like you, your engine rebuild might cost considerably more than a stock engine rebuild/hop-up. The most popular route for wild engines include the big three domestic car producers: GM, Ford, and MOPAR.  
  
The 454 BBC is often considered the ultimate ''readily available'' hot rod powerplant. However, over time the Chrysler Hemi, Chevy W-motor, Pontiac, AMC and the Boss 429 Ford have all had a resurgence since Edelbrock (and in some cases other manufacturers) have made alumimun cylinder heads and in some cases new aftermarket blocks available, as well as all the other necessary parts and pieces.
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The 454 BBC is often considered the ultimate ''readily available'' hot rod powerplant. However, over time the Chrysler Hemi, Chevy W-motor, Pontiac, AMC and the Boss 429 Ford have all had a resurgence since Edelbrock (and in some cases other manufacturers) have made aluminum cylinder heads and in some cases new aftermarket blocks available, as well as all the other necessary parts and pieces.
  
 
==Locating an engine to rebuild==
 
==Locating an engine to rebuild==
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Pushrods can be pulled and placed in a shallow pan for cleaning and possible reuse.  
 
Pushrods can be pulled and placed in a shallow pan for cleaning and possible reuse.  
  
Head bolts should be removed and inserted in a cardboard template to make note of there location.  
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Head bolts should be removed and inserted in a cardboard template to make note of their location.  
  
 
Prying up with a pry bar in the intake ports to cause separation of the head from the block, watch for coolant spills. Use a wide blade screwdriver to leverage the heads up off the block and dowel pins. Remove the heads to a solid work bench for inspection.  
 
Prying up with a pry bar in the intake ports to cause separation of the head from the block, watch for coolant spills. Use a wide blade screwdriver to leverage the heads up off the block and dowel pins. Remove the heads to a solid work bench for inspection.  
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Remove lifters from their bores; use a hook or removal tool and carb cleaner spray to remove the hard ones. Keep the lifters in order if they are to be reused. Drain the oil then pull the crank pulley, timing cover and the oil pan. Remove the timing gears and chain. Pull the camshaft. Remove the oil pump and drive rod. Before loosening the rod caps, use an engraving tool to ID the rods and caps with the cylinder number they go to. This is preferred to using a number set or center punch, but if done carefully this is still OK to do. Be sure to use only as much force as needed to get a legible number or marking and no more.  
 
Remove lifters from their bores; use a hook or removal tool and carb cleaner spray to remove the hard ones. Keep the lifters in order if they are to be reused. Drain the oil then pull the crank pulley, timing cover and the oil pan. Remove the timing gears and chain. Pull the camshaft. Remove the oil pump and drive rod. Before loosening the rod caps, use an engraving tool to ID the rods and caps with the cylinder number they go to. This is preferred to using a number set or center punch, but if done carefully this is still OK to do. Be sure to use only as much force as needed to get a legible number or marking and no more.  
  
Mark the caps in the same order as the firing order with a viberatory etcher. If you use a center punch or numbebered punch set, use a light touch so as to not distort anything.
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Mark the caps in the same order as the firing order with a vibratory etcher. If you use a center punch or numbebered punch set, use a light touch so as to not distort anything.
  
 
Pull off the cap on ONE rod and using a hardwood block, tap out the piston, then return the cap to that rod. Then remove the rest of the rods.  
 
Pull off the cap on ONE rod and using a hardwood block, tap out the piston, then return the cap to that rod. Then remove the rest of the rods.  
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2. You might want to research using special lifters or treatments that help prevent cam lobe/lifter failure. Some options are:
 
2. You might want to research using special lifters or treatments that help prevent cam lobe/lifter failure. Some options are:
 
*Hard-faced lifters with a stellite face on the lifter crown that will resist scuffing.  
 
*Hard-faced lifters with a stellite face on the lifter crown that will resist scuffing.  
*Comp Cams has an optional nitriding process that can be applied to any of their cams fr around $100 over he cost of the cam.  
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*Comp Cams has an optional nitriding process that can be applied to any of their cams for around $100 over he cost of the cam.  
 
*[http://www.4secondsflat.com/Composite%20lifters.htm SM Composite lifters], ~$700/set.   
 
*[http://www.4secondsflat.com/Composite%20lifters.htm SM Composite lifters], ~$700/set.   
 
*[http://www.4secondsflat.com/SM%20Tool%20Steel%20Lifters.htm SM Tool Steel lifters], ~$485-$625.  
 
*[http://www.4secondsflat.com/SM%20Tool%20Steel%20Lifters.htm SM Tool Steel lifters], ~$485-$625.  
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9. Pre-oil the motor with a drill motor and oil pump primer tool such as [http://www.jegs.com/i/JEGS-Performance-Products/555/23640/10002/-1?parentProductId=754806 this one from Jegs]. Put a socket on the harmonic damper retaining bolt and rotate the motor through at least 2 full revolutions while priming.
 
9. Pre-oil the motor with a drill motor and oil pump primer tool such as [http://www.jegs.com/i/JEGS-Performance-Products/555/23640/10002/-1?parentProductId=754806 this one from Jegs]. Put a socket on the harmonic damper retaining bolt and rotate the motor through at least 2 full revolutions while priming.
  
10. At the end of your 20 minute break-in period, drop the oil and filter and change them out. Drive the vehicle for 30 miles, altering the speed and letting the motor rev down from 60 mph to 20 mph with your foot off the gas pedal. Drop the oil and filter and repeat the EOS again. Change the valve springs to the ones that came with the cam kit. Drive for 500 miles and drop the oil and filter again.
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10. At the end of the cam/lifter break-in period, change the oil and filter. <br>
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{{Note1}}For more info on engine break in, see the links at the beginning of this section.
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==Compression ratio calculators==
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*[http://www.wheelspin.net/calc/calc2.html Static compression ratio]
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*[http://www.wallaceracing.com/dynamic-cr.php Wallace Racing DCR calculator]
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*[http://www.empirenet.com/pkelley2/DynamicCR.html Kelly DCR calculator]
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*[http://www.uempistons.com/calc.php?action=comp2 KB/Silvolite DCR calculator]
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*[http://www.rbracing-rsr.com/comprAdvHD.htm RSR DCR calculator]
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{{Note1}} Some dynamic compression rtatio calculators (like KBs) ask for an additional 15 degrees of duration be added to the IVC @ 0.050" lift point figure. This works OK on older, slower ramped cam lobes, but the faster lobe profiles may need to have 25 degrees or more added to be accurate.
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{{Note1}}If the intake valve closing (IVC) point isn't known, it can be calculated:
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# Divide the intake duration by 2
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# Add the results to the lobe separation angle (LSA)
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# Subtract any ground-in advance
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# Subtract 180
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This result does not need to have any amount added to the IVC point, like the KB calculator calls for.
  
 
==Related resources==
 
==Related resources==

Latest revision as of 10:47, 23 April 2020

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