The 4-Cylinder Engine Short Block High-Performance Manual

Introduction 5 Using this book & essential information 11 Chapter 1: Buying a standard used engine 13 Checking engine condition 14 Summary of checks 17 Chapter 2: Buying a used high-performance engine 18 What to check in unused/rebuilt engines 19 Chapter 3: Choosing replacement parts 21 Pistons 21 Cast pistons 21 Forged pistons 22 Piston rings 23 Top ring 23 Second ring 24 Three-piece oil control ring 24 Summary 24 Main & connecting rod bearings 24 Camshaft bearings (in block cams) 25 Connecting rod bolts 25 Gaskets 25 O-Ringing Blocks 26 Chapter 4: Plain bearing basics 28 Bearing tunnels 28 Bearing shell location tabs 29 Fitting main bearing shells 29 Fitting big end bearings 30 Chapter 5: Cylinder block - checking 34 Checking main bearing tunnel sizes 34 Check fitting main bearing shells 36 Checking bearing crush 36 Measuring main bearing inside diameters 37 Chapter 6: Cylinder block - preparation 39 Cleaning components 39 Cast iron components 39 Aluminium components 39 -------------------------------------------------------------------------------- Preparation before cleaning 39 Cleaning after parts have been in the tank 40 Crack & porosity testing 41 Iron blocks 41 Aluminium blocks 41 Threaded holes 42 Summary 42 Drain tap 42 Strapping welch (freeze) & camshaft plugs 43 Block decking 43 Reboring 44 Cylinder block boring machines 45 Final block detailing 46 Install camshaft bearings (if applicable) 46 Machined surface protection 46 Chapter 7: Connecting rods - preparation 47 Piston pin retention and little ends 49 Circlip piston pin retention 50 Interference fit piston pin retention 51 Connecting rod big end tunnel resizing 52 Big end bore honing 54 Connecting rod bolts 55 Checking connecting rod bolts for stretch 56 Aftermarket connecting rods 56 Bearing crush 57 Optimum big end bearing clearance 57 Big end bearing diameters 58 Chapter 8: Crankshaft 59 Checking the crankshaft 59 Crankshaft preparation 60 Crankshaft regrinding 61 Check fitting the connecting rods to the crankshaft 62 Flywheel dowelling 63 Chapter 9: Engine balance 64 Piston sets 64 Connecting rods 65 Crankshaft 65 Flywheels 65 Chapter 10: Camshaft and lifters 66 Used camshafts 66 Reground camshafts 67 -------------------------------------------------------------------------------- Lifters 68 Summary 68 Chapter 11: Crankshaft - check fitting 69 Camshaft installation (if in block) 69 Crankshaft installation 70 Thrust bearings 70 'Check fitting' the crankshaft to the block 71 Chapter 12: Timing chain 75 Fitting timing chains 75 Camshaft timing 76 Accurate valve timing 77 Chapter 13: Valve reliefs & fitting pistons to connecting rods 78 Piston valve reliefs 78 Accurate valve relief location 79 Valve relief diameters 79 Fitting pistons to connecting rods 80 Interference fit piston pins 80 Circlip retained piston pins 81 Chapter14: Pistons and connecting rods - installation 84 Piston rings 84 Measuring end gaps 84 Altering ring gaps 85 Side clearance 85 Radial depth of the ring groove 85 Fitting rings to pistons 86 Oil control rings 86 Compression rings 87 Chapter 15: Camshaft & ignition timing marks 90 Checking top dead centre 90 Ignition timing marks 92 Camshaft timing marks 92 Degree marking the crankshaft pulley 93 Checking camshaft timing (in-block cams) 94 Chapter 16: Oiling system 97 Stock sumps (oil pans) 97 Windage tray & baffle 97 Increasing oil capacity 98 Aluminium sumps 99 Engine installation angle 99 Oil pumps 99 Crankcase ventilation 100 Oil & filter 100