Engine Rebuild Dashboard

Start

Engine Block
Inspection (1 of 2)

Crankshaft
Inspection

Valve Head
Disassembly

Engine Block
Inspection (2 of 2)
B

Valve Head
Inspection
D

Valve Head
Reconditioning
E

Assembly (1 of 2)

Assembly (2 of 2)

I
K; L; M; N

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End

Engine Block Inspection (1 of 2)

Start

Perform visual
inspection of
engine
A01

No defects

Check ID and
casting numbers

Task Description

A02

Inspect
components

A03

A04

Seeping core plugs

Distributor - wooble & looseness

Leaking water pump o ring

Alternator - belt, pulley noise

Cracked rubber on Harmonic

Balancer

Clutch assembly

Signs of overheating
Excessive gasket sealer from
previous work

Within OEM spec

Remove ridge

Ridge removed

A05

Oil pan
removed

Remove oil pan

A06

Remove valve
heads
A07

Ridge=point where rings meet bore

Heads removed
Engine Block
Inspection
(2 of 2)

Remove piston
and rod
Pistons removed
assemblies
A08

Remove and
inspect crankshaft

Crankshaft
removed

A09
B

Remove
camshaft,
balancer shafts,
and auxiliary
drives
A10

Removed

Use rod journal protectors

Store correctly

Put caps back on rods once

removed

Keep old bearings in order, check

for wear/excess dirt

Pay attention to end play shims and

spacers

Rod journal protectors

Put main caps back on block and

torque to spec

Remove bearings, pay attention to

position

C01

Crankshaft Inspection
Engine Block
Inspection
(1 of 2)

A10

Crankshaft
removed

Perform visual
inspection

Within OEM
spec

Measure
crankshaft

B01

If crank can be
machined

Mark for
identification

B02

Cracks and signs of overheating

B03

Journal diameter
Out of round
Taper
Run out
Dial gauge
Dial bore gauge

Dial Gauge
Marked
Machine Shop

Measure after
grinding

Within OEM
spec

Change pilot
bearing

B04

Engine balancing
required

B05

Needed for correcting bearings

Use rifle brush through oil assages
to clean out debris after grinding

No balancing
required

Supply machine
shop will needed
parts
B06

A10

Rifle brush
Dial bore gauge
Engine Block
Inspection (1 of
2)

Dial gauge

Dial bore gauge

Sent to
machine
shop

G01

Engine Block Inspection (2 of 2)

A10

Remove core
plugs, brackets,
guide pins, ect...
C01

Removed

Visually check
block for cracks

No
cracks

Magnaflux block

C02

No
cracks

C03

Magnaflux cast iron and steel only

Engine Block
Inspection
(1 of 2)

Dye penetrant aluminum blocks

Check deck
surface for
flatness
C04
Straight edge
Feeler gauge

Magnaflux
Dye penetrant

Within OEM spec

Valve Head
Disassembly

Measure cylinder
bore
C05

Within
OEM
spec

Taper

Check for
discoloration and
washboard
C06

Within
OEM
spec

Use rigid stone hone to identify

washboard

Out of round

Rigid stone hone

Dial bore gauge

Check main
bearing bores
C07

Within
OEM
spec

D01

Alignment
Out of round
Round straight edge
Feeler gauge
Dial bore gauge

Feeler Gauge

Rigid Stone
Hone

Valve Head Disassembly

Engine Block
Inspection
(2 of 2)

Valve Spring Compression

Tool

C07
Compress valve
spring
D01

Spring
compres
sed

Valve spring compression tool

Remove keepers

Keepers
removed

Remove spring
and shims

D02

D03

Keep spring compressed

Keep in order

Valve spring compression tool

Removed
More valves
to remove

Valve Head
Inspection

Remove valve

Valves
removed

Clean heads and

valves

D04

Do not force out of guides

Heads and
vales cleaned

D05

If possible have shot peened or

glass beaded
Solvent

E01

Valve Head Inspection

Valve Head
Disassembly

Straight Edge
D05

Identify cracks

No
cracks

Feeler Gauge

Check for flatness

E01

E02

Magnaflux

Straight edge

Dye penetrant

Feeler gauge

Within
OEM
spec

Check for worn

guides
E03
Dial indicator

Dial Indicator

Within OEM spec

Check for seat

recession
E04

Within
OEM
spec

Check for worn

stems
E05

Within
OEM
spec

Check for worn

keeper grooves
E06

Micrometer

Within OEM spec

Check for thin

margins on valves

Within
OEM
spec

E07

Measure valve
springs

Within
OEM spec

F01

Micrometer

E08

Margins thinner on intake valves

Tension - compress spring to

designated length

Micrometer

Free length
Squareness
Spring compressor
Micrometer
90 degree straight edge

Valve Head
Reconditioning

Valve Head Reconditioning

E08

Recondition valve
guides

Guides
reconditioned

Replace valve
seats

F01

Seats
replaced

Reface all
acceptable valves

F04

F02
Stones or cutters

Valve Head
Inspection

Valves refaced

Machine valve
seats

Seats
machined

F03

Lubricate valve
stems

Stems
lubricated

Install valve seals

F05

Stones or cutters

F06

Engine oil

May be band, umbella, or PC type

Pay attention to the order of
assembly

Seals installed
Assembly (1 of 2)

Assemble valve
heads
F07

Heads
assembled

Check for leaks

No leaks

F08

Liquid test or vacuum test

H01

When Block is Sent to Machinist

A10

Machinist
work needed

Mark block for

identification

Marked

G01

Send all pistons to

machinist

Pistons
sent

G02

Identifies block when returned

Engine Block
Inspection (2 of
2)

If block is being bored

Block should be machined to match
pistons

Send old piston

and rod
assemblies
G03

New pistons will be installed on

rods
Have machine shop identify which
cylinder corresponds to which
piston

Sent

Valve Head
Disassembly

Check rods for

reconditioning
G04

Within
OEM
spec

Connecting rods should always

recieve new bolts

Install new cam

bearings
G05

Bearings
installed

Inform machinist
of any broken
bolts
G06

Mark with paint

Find out
estimated
completion date
G07

Machine
work
returned

D01

Assembly (1 of 2)
F08

Clean block

Block clean

Check all
dimensions

H01

Dimensions
correct

Wash block again

H02

Use soapy water, then air dry

H03

Machine shops do make mistakes,

double check their work

Use hot soapy water, then blow dry

Scrub brush

Check ring end gaps

Valve Head
Reconditioning

Check oil clearances

Block washed

Blow out all bolt

holes

Bolt holes clear

H04

Install oil gallery

plugs and core
plugs
H05

Prior to installing fasteners

Plugs installed

Install cam shaft

H06

Use hardening sealer, never

silicone

Use high pressure grease

Hardening sealer

Cam installed

Install main
bearings

Assembly (2 of 2)

Bearings
installed

Install crankshaft
and main caps

H07

Position sensitive
Clean and dry main bearing bores
and backs of bearings
Install rear main seal
Lubricate all main bearings and lip
on rear main seal

Dial Indicator

H08

Caps sensitive to position and

direction
Torque from center out in 3 stages
Rotate crank to ensure it is not
binding
Check end play
Dial indicator
Pry bar

Pry Bar

Crank
installed

I01

Assembly (2 of 2)
H08

Install timing
chain

Chain
installed

Degree cam

I01

Cam degreed

I02

Install piston and

rod assemblies
I03

J
Assembly (1 of 2)

Check OEM specs

Stagger ring end gaps to reduce

blowby

Align timing marks

Piston Ring
Compressor

Be sure oil expander is butted

Check OEM specs
Inastall and torque rod caps as you
go
Rotate crank after installing each
piston
Piston ring compressor
Rod protectors

Pistons installed
Head
gasket
installed

Install head
gasket

Install heads

I04

Heads
installed

I05

May be directional

Install valve train

I06

Pay attention to length and location

Lubricate parts as necessary

Tube threads with OEM lubricant or

sealer

Adjust valves as necessary

(minimum up/down movement,
then torque 3/4 turn)

Torque in 3 stages using OEM

pattern

Valve train installed

Install the rest of

pans, covers,
pulleys, ect...
I07

Installed

Paint as required
I08

Painted

Double check
everything
I09

Engine
rebuild
complete

End

Degree Camshaft

I02

Assembly (2 of 2)

Install degree
wheel on
crankshaft
J01

Degree wheel
installed

Install pointer on front of engine

block

Install dial
indictator on flat
surface over
cylinder 1
J02

Install dial
indictator

Find TDC of
cylinder 1
J03
K
Dial incator

Dial indicator

Pointer

Degree wheel

Flat surface for dial indicator

Pointer (coat hanger works well)

Degree wheel

Find TDC

Assembly (2 of 2)

Determine intake
lobe centerline

Centerline
determined

Measure lobe lift

J05

Lobe lift
determined

J04

M
Dial indicator
Pointer
Flat surface for dial indicator
Degree wheel

Dial Indicator

I03

Find TDC
Degree Camshaft

J03

Turn engine to
approximately
TDC (top dead
center)
K01

Engine at
approx. TDC

Rotate engine
counterclockwise
.050"
K02

Engine
rotated

Rotate engine
.100" clockwise
K03

Record reading on degree wheel

Record reading on degree wheel

Degree wheel

Go past then return to remove

slack in chain

Go past then return to remove

slack in chain

Dial indicator

Degree wheel

Degree wheel

Dial indicator

Dial indicator

Zero dial indicator

Rotated

Add both readings

together and
divide by 2
K04

Added and
divided

Move pointer to
the degree equal
to that number
K05
Pointer
Degree wheel

Pointer
moved

Rotate engine to 0
degrees

Engine
rotated

K06
Intake Lobe
Centerline
This should be TDC of cylinder 1,
this is the point at which the dial
indicator changes direction
If direction doesn't, repeat process
until TDC is found
Degree wheel
Dial indicator

Dial Indicator

L01

Determine intake lobe centerline

Find TDC

K06

Place dial
indicator on #1
intake lobe
L01

Dial indicator
installed

Rotate engine
counterclockwise
until you achieve
maximum lift
L02

Maximum lift
found

Zero dial indicator

L03
Dial Indicator

Dial Indicator
This is the point at which the
degree wheel changes direction

Dial indicator zeroed

Measure lobe lift

Rotate engine
counterclockwise
.050"
L04

Rotated

Rotate engine
.100" clockwise

Rotated

L05

Record reading on degree wheel

Record reading on degree wheel

Go past then return to remove

slack in chain

Go past then return to remove

slack in chain

Degree wheel

Degree wheel

Dial indicator

Dial indicator

Add both readings

together and
divide by 2
L06

Intake lobe
centerline
determined

This number is your intake lobe

centerline

Dial Indicator

M01

Measure lobe lift

Intake Lobe
Centerline

L06

Dial Indicator

Place dial indictor

on #1 intake lobe
M01

Dial
indicator
installed

Rotate engine to
intake lobe
centerline
M02

Dial Indicator

Centerline
found

Zero dial indicator

M03
Dial Indicator

Degree wheel
Dial indicator

Dial indicator zeroed

Assembly (2 of 2)

Rotate engine
clockwise, count
on dial indictor lift
trabel
M04

Lobe lift
recorded

This measurement is lobe lift

Dial Indicator

Multiply lobe lift by

rocker arm ratio
M05

The product is valve lift

Lobe lift
Rockerarm ratio

Valve lift
found

I02