1. Remove all sharp edges created by machining Combustion chamber
Engine assembly
Before final cleaning
Remove all sharp edges created by machining
Combustion chamber
Crankshaft oil holes
Top & bottom of cylinders
Oil pump gears
Clean all internal & external threads
Chamfer top of bolt holes
Use tap or die for restoring threads
Copyright 2003 Gary Lewis – Dave Capitolo

2. Engine assembly
Before final cleaning
Check lifter bores for rust & burrs
Use glaze breaker if necessary
Check cam bores for burrs
Could distort cam bearings if not deburred

3. Engine assembly
Final cleaning
Only after all machining is done
Use detergent hot tank
Insufficient cleaning results in . . .
Piston ring wear
Bearing wear
Valve stem wear

4. Engine assembly
Final cleaning
Coat cylinders & decks with clean oil to prevent rust
Coat valves, seats, & decks with clean oil

5. Engine assembly
Assembling cylinder heads
Guides must be clean & lubricated
Install valves with oil
Protect seals with plastic sleeve on valve
Check cam rotation on OHC heads

6. Engine assembly
Installing core plugs
Measure bore diameter to assure correct plugs
Use deep plugs where possible
Coat outer edges for sealing
Drive plug in slightly below block surface

7. Engine assembly
Sealing coolant, lubricants, & combustion
Typical cooling system is °F
Typical oil pressure range is PSI
Gasket must not restrict flow
Fire rings protect gasket material & cyl pressure

8. Engine assembly
Chemical sealers
Sometimes used in place of gaskets
Silicone sealers (RTV) are flexible & temp resistant
Anaerobic sealers – Absence of air

9. Engine assembly
Head gaskets
Metal-asbestos replaced with ceramic laminate
Composite core copper
Good compressibility, low compression, 60AA
Composite core steel
Heat resistant, high compression, 60AA
Coated gaskets
Resin, polymer, better sealing of fluids
MLS (Multi layer steel)
For dissimilar metals, 15-20AA

10. Engine assembly
Head gaskets
Stainless steel face
On one side for high cylinder head temps,
GM diesels
Embossed steel
Improved heat transfer, ridges provide crush
for sealing, high compression, 30-50AA
No-retorque
Polymer coated, printed with silicone for
low clamping force areas

11. Engine assembly
Gaskets
Cork used on valve covers, lifter covers, oil pans
Stretches & shrinks
Synthetic rubber
Compressible, does not wick, resists heat

12. Engine assembly
Crankshaft seals
Rope type seals must be fitted
Lip type seals
Lips face the oil
Nitril & neoprene are common
Viton withstands loads & heat

13. Engine assembly
OHV assembly
Only after sub-assemblies have been inspected
Install core plugs
Install chamfered cam bearings

14. Engine assembly
OHV assembly
Check cam for straightness
Check cam fit in bearings & scrape as needed
Cam must rotate freely
Blow all passages clear

15. Engine assembly
OHV assembly
Grease cam to protect lobes & install cam
Install oil galley plugs with sealer on outer edges

16. Engine assembly
OHV assembly
Install rear main seal (two piece seal)
Install main bearings
Install crankshaft & check clearance

17. Engine assembly
OHV assembly
Oil all bearings & position thrust main cap
Torque all main caps
Check crankshaft endplay

18. Engine assembly
OHV assembly
Install thrust plate & timing set
Check camshaft endplay

19. Engine assembly
OHV assembly
Install piston assemblies
Loctite & torque rod nuts
Check rod side clearance

20. Engine assembly
OHV assembly
Install oil pump & drive shaft
Verify cam timing at split overlap
Install timing cover

21. Engine assembly
OHV assembly
Install oil pan
Torque heads onto block
Install rocker arms & pushrods
Adjust valves & test

22. Engine assembly
OHC assembly differences
Balance shaft bearings
Crank & cam must be set to TDC before installation
Some timing covers are installed before head or pan
Timing belts and covers are installed last

23. Engine assembly
Sealing crankshafts
Bearing clearance must not be excessive
Seal surfaces must be concentric with journals

24. Engine assembly
Sealing crankshafts
Seals should be within .005” TIR of crank centerline
Poor seal concentricity with main caps not centered

25. Engine assembly
Sealing crankshafts
Seal surfaces must not have grooves

26. Engine assembly
Sealing crankshafts
Rope type rear main seals
Coated with dry lubricant
Do not oil
Fitted with round stock, same size as seal surface
on crankshaft

27. Engine assembly
Sealing crankshafts
Lip seal rear main
Sealer on outer edge
Oil on sealing surface
Thin coat of sealer at rear of parting line

28. Engine assembly
Sealing crankshafts
Side seals on rear main
Installed with nail or soaked in oil

29. Engine assembly
Valve timing
Check service manual for timing marks
Confirm by checking split overlap
Dual pattern cams don’t have equal lift & duration

30. Engine assembly
Valve timing
Valve timing can be adjusted with keys & bushings

31. Engine assembly
Pistons & rings
End gap .003” per inch of cylinder bore
Hypereutectic pistons use twice as much
End gap is increased by filing
End gap increases .003” for each .001” bore increase

32. Engine assembly
Pistons & rings
Oil control expander, then rails
Stagger end gaps
Lower compression ring, then top
Stagger end gaps
Oil grooves & check for rotation

33. Engine assembly
Piston types
Cast aluminum – OEM pistons
Forged aluminum – Stronger & better heat dissipation
Hypereutectic – High silicon content
Lighter
Good wear characteristics
Tighter clearances due to low expansion rate
Requires more ring end gap

34. Engine assembly
Piston skirts
Slipper skirts – Cam ground
Clearance for counterweights
Steel struts help piston expand with pin
Full skirt– Used in longer stroke engines
Barrel shaped skirt– Largest diameter is in the center

35. Engine assembly
Before attaching heads to blocks
Surfaces clean and flat
Threads clean
Sharp edges de-burred
Alignment dowels installed
Check gasket direction
Do not use sealer on coated gaskets
Look up torque specs & sequence

36. Engine assembly
Attaching heads to blocks
Threads lubricated with oil or sealer
Torque in sequence in 3 steps
TTY bolts may need to be replaced

37. Engine assembly
Rocker arms
Check for correct offset of rocker arms
Check rocker shafts for correct direction

38. Engine assembly
Valve adjustment
Non-hydraulic valve trains
Piston at TDC, compression
Adjust valves that are closed & rotate engine
Adjustable hydraulic valve trains
Zero lash plus pre-load
Collapse lifter and set clearance
Non-adjustable hydraulic valve trains
Torque to specs

39. Engine assembly
Pre-oiling
Push rod engine
Install lifters
Rotate oil pump with speed handle
Crank driven oil pumps
Pre-lubricator used to pre-oil engines
Assemble oil pump with grease for priming
Crank engine with no spark plugs, fuel, or ignition

40. Engine assembly
Run-in stand
Oil pressure & circulation
Compression
Noises
Gaskets & seals
Lifter rotation