Buy or Rebuild-
Now that you have determined that your engine is worn out, you must make some decisions. The question of whether or not an engine is worth rebuilding is largely a subjective matter and one of personal worth. Is the engine a popular one, or is it an obsolete model- Are parts available- Will it get acceptable gas mileage once it is rebuilt- Is the car it's being put into worth keeping- Would it be less expensive to buy a new engine, have your engine rebuilt by a pro, rebuild it yourself or buy a used engine from a salvage yard- Or would it be simpler and less expensive to buy another car- If you have considered all these matters and more, and have still decided to rebuild the engine, then it is time to decide how you will rebuild it.
A complete rebuild or overhaul of an engine involves replacing all of the moving parts (pistons, rods, crankshaft, camshaft, etc.) with new ones and machining the non-moving wearing surfaces of the block and heads. Unfortunately, this may not be cost effective. For instance, your crankshaft may have been damaged or worn, but it can be machined undersize for a minimal fee.
So, as you can see, you can replace everything inside the engine, but, it is wiser to replace only those parts which are really needed, and, if possible, repair the more expensive ones. Later in this section, we will break the engine down into its two main components: the cylinder head and the engine block. We will discuss each component, and the recommended parts to replace during a rebuild on each.Cylinder Block Reconditioning
A thorough overhaul or rebuild of an engine block would include replacing the pistons, rings, bearings, timing belt/chain assembly and oil pump. For OHV engines also include a new camshaft and lifters. The block would then have the cylinders bored and honed oversize (or if using removable cylinder sleeves, new sleeves installed) and the crankshaft would be cut undersize to provide new wearing surfaces and perfect clearances.
However, your particular engine may not have everything worn out. What if only the piston rings have worn out and the clearances on everything else are still within factory specifications- Well, you could just replace the rings and put it back together, but this would be a very rare example. Chances are, if one component in your engine is worn, other components are sure to follow, and soon. At the very least, you should always replace the rings, bearings and oil pump. This is what is commonly called a 'freshen up'.Assembly
- Before you begin assembling the engine, first give yourself a clean, dirt free work area. Next, clean every engine component again. The key to a good assembly is cleanliness.
- Mount the engine block into the engine stand and wash it one last time using water and detergent (dishwashing detergent works well). While washing it, scrub the cylinder bores with a soft bristle brush and thoroughly clean all of the oil passages. Completely dry the engine and spray the entire assembly down with an anti-rust solution such as WD-40® or similar product.
- Take a clean lint-free rag and wipe up any excess anti-rust solution from the bores, bearing saddles, etc. Repeat the final cleaning process on the crankshaft. Replace any freeze or oil galley plugs which were removed during disassembly.
- Remove the main bearing inserts from the block and bearing caps.
- If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct undersize bearing. Be sure that the bearing inserts and bearing bores are clean. Foreign material under inserts will distort bearing and cause failure.
- Place the upper main bearing inserts in bores with tang in slot.
- Install the lower main bearing inserts in bearing caps.
- Clean the mating surfaces of block and rear main bearing cap.
- Carefully lower the crankshaft into place. Be careful not to damage bearing surfaces.
- Check the clearance of each main bearing by using the following procedure:
- Place a piece of Plastigage® or its equivalent, on bearing surface across full width of bearing cap and about 1 / 4 inch off center.
- Install cap and tighten bolts to specifications. Do NOT turn crankshaft while Plastigage® is in place.
- Remove the cap. Using the supplied Plastigage® scale, check width of Plastigage® at widest point to get maximum clearance. Difference between readings is taper of journal.
- If clearance exceeds specified limits, try a 0.001 inch or 0.002 inch undersize bearing in combination with the standard bearing. Bearing clearance must be within specified limits. If standard and 0.002 inch undersize bearing does not bring clearance within desired limits, refinish crankshaft journal, then install undersize bearings.
- Install the rear main seal.
- After the bearings have been fitted, apply a light coat of engine oil to the journals and bearings. Install the rear main bearing cap. Install all bearing caps except the thrust bearing cap. Be sure that main bearing caps are installed in original locations. Tighten the bearing cap bolts to specifications.
- Install the thrust bearing cap with bolts finger-tight.
- Pry the crankshaft forward against the thrust surface of upper half of bearing.
- Hold the crankshaft forward and pry the thrust bearing cap to the rear. This aligns the thrust surfaces of both halves of the bearing.
- Retain the forward pressure on the crankshaft. Tighten the cap bolts to specifications.
- Measure the crankshaft endplay as follows:
- Mount a dial gauge to the engine block and position the tip of the gauge to read from the crankshaft end.
- Carefully pry the crankshaft toward the rear of the engine and hold it there while you zero the gauge.
- Carefully pry the crankshaft toward the front of the engine and read the gauge.
- Confirm that the reading is within specifications. If not, install a new thrust bearing and repeat the procedure. If the reading is still out of specifications with a new bearing, have a machine shop inspect the thrust surfaces of the crankshaft, and if possible, repair it.
- Rotate the crankshaft so as to position the first rod journal to the bottom of its stroke.
- Install the cylinder head(s) using new gaskets.
- Install the timing sprockets/gears and the belt/chain assemblies.
Install the timing cover(s) and oil pan. Refer to your notes and drawings made prior to disassembly and install all of the components that were removed. Install the engine into the vehicle.Pistons & Connecting Rods
- Before installing the piston/connecting rod assembly, oil the pistons, piston rings and the cylinder walls with light engine oil. Install connecting rod bolt protectors or rubber hose onto the connecting rod bolts/studs. Also perform the following:
- Select the proper ring set for the size cylinder bore.
- Position the ring in the bore in which it is going to be used.
- Push the ring down into the bore area where normal ring wear is not encountered.
- Use the head of the piston to position the ring in the bore so that the ring is square with the cylinder wall. Use caution to avoid damage to the ring or cylinder bore.
- Measure the gap between the ends of the ring with a feeler gauge. Ring gap in a worn cylinder is normally greater than specification. If the ring gap is greater than the specified limits, try an oversize ring set.
- Check the ring side clearance of the compression rings with a feeler gauge inserted between the ring and its lower land according to specification. The gauge should slide freely around the entire ring circumference without binding. Any wear that occurs will form a step at the inner portion of the lower land. If the lower lands have high steps, the piston should be replaced.
- Unless new pistons are installed, be sure to install the pistons in the cylinders from which they were removed. The numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore. If a connecting rod is ever transposed from one engine or cylinder to another, new bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number. The notch on the piston head goes toward the front of the engine.
- Install all of the rod bearing inserts into the rods and caps.
- Install the rings to the pistons. Install the oil control ring first, then the second compression ring and finally the top compression ring. Use a piston ring expander tool to aid in installation and to help reduce the chance of breakage.
- Make sure the ring gaps are properly spaced around the circumference of the piston. Fit a piston ring compressor around the piston and slide the piston and connecting rod assembly down into the cylinder bore, pushing it in with the wooden hammer handle. Push the piston down until it is only slightly below the top of the cylinder bore. Guide the connecting rod onto the crankshaft bearing journal carefully, to avoid damaging the crankshaft.
- Check the bearing clearance of all the rod bearings, fitting them to the crankshaft bearing journals. Follow the procedure in the crankshaft installation above.
- After the bearings have been fitted, apply a light coating of assembly oil to the journals and bearings.
- Turn the crankshaft until the appropriate bearing journal is at the bottom of its stroke, then push the piston assembly all the way down until the connecting rod bearing seats on the crankshaft journal. Be careful not to allow the bearing cap screws to strike the crankshaft bearing journals and damage them.
- After the piston and connecting rod assemblies have been installed, check the connecting rod side clearance on each crankshaft journal.
- Prime and install the oil pump and the oil pump intake tube.
- Install the auxiliary and/or balance shaft(s).
Before the engine and its components are inspected, they must be thoroughly cleaned. You will need to remove any engine varnish, oil sludge and/or carbon deposits from all of the components to insure an accurate inspection. A crack in the engine block or cylinder head can easily become overlooked if hidden by a layer of sludge or carbon.
Most of the cleaning process can be carried out with common hand tools and readily available solvents or solutions. Carbon deposits can be chipped away using a hammer and a hard wooden chisel. Old gasket material and varnish or sludge can usually be removed using a scraper and/or cleaning solvent.
Extremely stubborn deposits may require the use of a power drill with a wire brush. If using a wire brush, use extreme care around any critical machined surfaces (such as the gasket surfaces, bearing saddles, cylinder bores, etc.). Use of a wire brush is NOT RECOMMENDED on any aluminum components.
An alternative to the mess and hassle of cleaning the parts yourself is to drop them off at a local garage or machine shop. They will, more than likely, have the necessary equipment to properly clean all of the parts for a nominal fee.
Remove any oil galley plugs, freeze plugs and/or pressed-in bearings and carefully wash and degrease all of the engine components including the fasteners and bolts. Small parts such as the valves, springs, etc., should be placed in a metal basket and allowed to soak.
Use pipe cleaner type brushes, and clean all passageways in the components. Use a ring expander and remove the rings from the pistons. Clean the piston ring grooves with a special tool or a piece of broken ring. Scrape the carbon off of the top of the piston. You should never use a wire brush on the pistons. After preparing all of the piston assemblies in this manner, wash and degrease them again.
When cleaning the cylinder head, remove carbon from the combustion chamber with the valves installed. This will avoid damaging the valve seats.Disassembly
The engine disassembly instructions following assume that you have the engine mounted on an engine stand. If not, it is easiest to disassemble the engine on a bench or the floor with it resting on the bell housing or transmission mounting surface. You must be able to access the connecting rod fasteners and turn the crankshaft during disassembly. Also, all engine covers (timing, front, side, oil pan, whatever) should have already been removed. Engines, which are seized or locked up, may not be able to be completely disassembled, and a core (salvage yard) engine should be purchased.
If not done during the cylinder head removal, remove the timing chain/belt and/or gear/sprocket assembly. Remove the oil pick-up and pump assembly and, if necessary, the pump drive. If equipped, remove any balance or auxiliary shafts. If necessary, remove the cylinder ridge from the top of the bore. See the cylinder ridge removal procedure earlier in this section.
Rotate the engine over so that the crankshaft is exposed. Use a number punch or scribe and mark each connecting rod with its respective cylinder number. The cylinder closest to the front of the engine is always number 1. However, depending on the engine placement, the front of the engine could either be the flywheel or damper/pulley end. Generally the front of the engine faces the front of the vehicle. Use a number punch or scribe and also mark the main bearing caps from front to rear with the front most cap being number 1 (if there are five caps, mark them 1 through 5, front to rear).
- Again, rotate the engine, this time to position the number one cylinder bore (head surface) up. Turn the crankshaft until the number one piston is at the bottom of its travel, this should allow the maximum access to its connecting rod.
- Remove the number one connecting rods fasteners and cap and place two lengths of rubber hose over the rod bolts/studs to protect the crankshaft from damage. Using a sturdy wooden dowel and a hammer, push the connecting rod up about 1 inch (25mm) from the crankshaft and remove the upper bearing insert.
- Continue pushing or tapping the connecting rod up until the piston rings are out of the cylinder bore. Remove the piston and rod by hand, put the upper half of the bearing insert back into the rod, install the cap with its bearing insert installed, and hand-tighten the cap fasteners.
- The only remaining component in the engine block should now be the crankshaft. Loosen the main bearing caps evenly until the fasteners can be turned by hand, and then remove them and the caps. Remove the crankshaft from the engine block. Thoroughly clean all of the components.
Now that the engine block and all of its components are clean, it's time to inspect them for wear and/or damage. To accurately inspect them, you will need some specialized tools:
If you Do NOT have access to the proper tools, you may want to bring the components to a shop that does.
Generally, you shouldn't expect cracks in the engine block or its components unless it was known to leak, consume or mix engine fluids, it was severely overheated, or there was evidence of bad bearings and/or crankshaft damage. A visual inspection should be performed on all of the components, but just because you don't see a crack does not mean it is not there.
Some more reliable methods for inspecting for cracks include Magnaflux®, a magnetic process or Zyglo®, a dye penetrant. Magnaflux® is used only on ferrous metal (cast iron). Zyglo® uses a spray on fluorescent mixture along with a black light to reveal the cracks. It is strongly recommended to have your engine block checked professionally for cracks, especially if the engine was known to have overheated and/or leaked or consumed coolant. Contact a local shop for availability and pricing of these services.Bearings
All of the engine bearings should be visually inspected for wear and/or damage. The bearing should look evenly worn all around with no deep scores or pits. If the bearing is severely worn, scored, pitted or heat blued, then the bearing, and the components that use it, should be brought to a machine shop for inspection. Full-circle bearings (used on most camshafts, auxiliary shafts, balance shafts, etc.) require specialized tools for removal and installation, and should be brought to a machine shop for service.Engine Block
Checking The Block Deck For Warpage
The top of the engine block where the cylinder head mounts is called the deck.
- Insure that the deck surface is clean of dirt, carbon deposits and old gasket material. Place a straightedge across the surface of the deck along its centerline and, using feeler gauges, check the clearance along several points.
- Repeat the checking procedure with the straightedge placed along both diagonals of the deck surface. If the reading exceeds 0.003 inch (0.076mm) within a 6.0 inch (15.2cm) span, or 0.006 inch (0.152mm) over the total length of the deck, it must be machined.
The cylinder bores house the pistons and are slightly larger than the pistons themselves. A common piston-to-bore clearance is 0.0015-0.0025 inch (0.0381mm-0.0635mm). Inspect and measure the cylinder bores. The bore should be checked for out-of-roundness, taper and size. The results of this inspection will determine whether the cylinder can be used in its existing size and condition, or a rebore to the next oversize is required (or in the case of removable sleeves, have replacements installed).
The amount of cylinder wall wear is always greater at the top of the cylinder than at the bottom. This wear is known as taper. Any cylinder that has a taper of 0.0012 inch (0.305mm) or more, must be rebored. Measurements are taken at a number of positions in each cylinder: at the top, middle and bottom and at two points at each position; that is, at a point 90° from the crankshaft centerline, as well as a point parallel to the crankshaft centerline.
The measurements are made with either a special dial indicator or a telescopic gauge and micrometer. If the necessary precision tools to check the bore are not available, take the block to a machine shop and have them mike it. Also if you don't have the tools to check the cylinder bores, chances are you will not have the necessary devices to check the pistons, connecting rods and crankshaft. Take these components with you and save yourself an extra trip.
For our procedures, we will use a telescopic gauge and a micrometer. You will need one of each, with a measuring range that covers your cylinder bore size.
- Position the telescopic gauge in the cylinder bore, loosen the gauges lock and allow it to expand.
- Hold the gauge square in the bore, 90° from the crankshaft centerline, and gently tighten the lock. Tilt the gauge back to remove it from the bore.
- Measure the gauge with the micrometer and record the reading.
- Again, hold the gauge square in the bore, this time parallel to the crankshaft centerline, and gently tighten the lock. Again, you will tilt the gauge back to remove it from the bore.
- Measure the gauge with the micrometer and record this reading. The difference between these two readings is the out-of-round measurement of the cylinder.
- Repeat steps 1 through 5, each time going to the next lower position, until you reach the bottom of the cylinder. Then go to the next cylinder, and continue until all of the cylinders have been measured.
The difference between these measurements will tell you all about the wear in your cylinders. The measurements which were taken 90° from the crankshaft centerline will always reflect the most wear. That is because at this position is where the engine power presses the piston against the cylinder bore the hardest. This is known as 'thrust wear'. Take the 90° measurement made at the top and compare it to your bottom measurement. The difference between them is the taper. When you measure your pistons, you will compare these readings to your piston sizes and determine piston-to-wall clearance.Engine Block Bearing Alignment
- Remove the main bearing caps and, if still installed, the main bearing inserts. Inspect all of the main bearing saddles and caps for damage, burrs or high spots. If damage is found, and it is caused from a spun main bearing, the block will need to be align-bored or, if severe enough, replacement. Any burrs or high spots should be carefully removed with a metal file.
- Place a straightedge on the bearing saddles, in the engine block, along the centerline of the crankshaft. If any clearance exists between the straightedge and the saddles, the block must be align-bored.
Align-boring consists of machining the main bearing saddles and caps by means of a flycutter that runs through the bearing saddles.Refinishing
Almost all engine block refinishing must be performed by a machine shop. If the cylinders are not to be rebored, then the cylinder glaze can be removed with a ball hone. When removing cylinder glaze with a ball hone, use a light or penetrating type oil to lubricate the hone. Do NOT allow the hone to run dry as this may cause excessive scoring of the cylinder bores and wear on the hone. If new pistons are required, they will need to be installed to the connecting rods. This should be performed by a machine shop as the pistons must be installed in the correct relationship to the rod or engine damage can occur.
Because the top piston ring does not travel to the very top of the cylinder, a ridge is built up between the end of the travel and the top of the cylinder bore.
Pushing the piston and connecting rod assembly past the ridge can be difficult, and damage to the piston ring lands could occur. If the ridge is not removed before installing a new piston or not removed at all, piston ring breakage and piston damage may occur.
There are several different types of ridge reamers on the market, none of which are inexpensive. Unless a great deal of engine rebuilding is anticipated, borrow or rent a reamer.
- Turn the crankshaft until the piston is at the bottom of its travel.
- Cover the head of the piston with a rag.
- Follow the tool manufacturers instructions and cut away the ridge, exercising extreme care to avoid cutting too deeply.
- Remove the ridge reamer, the rag and as many of the cuttings as possible. Continue until all of the cylinder ridges have been removed.
Anything that generates heat and/or friction will eventually burn or wear out (for example, a light bulb generates heat, therefore its life span is limited). With this in mind, a running engine generates tremendous amounts of both; friction is encountered by the moving and rotating parts inside the engine and heat is created by friction and combustion of the fuel.
However, the engine has systems designed to help reduce the effects of heat and friction and provide added longevity. The oiling system reduces the amount of friction encountered by the moving parts inside the engine, while the cooling system reduces heat created by friction and combustion. If either system is not maintained, a break-down will be inevitable. Therefore, you can see how regular maintenance can affect the service life of your vehicle.
If you Do NOT drain, flush and refill your cooling system at the proper intervals, deposits will begin to accumulate in the radiator, thereby reducing the amount of heat it can extract from the coolant. The same applies to your oil and filter; if it is not changed often enough it becomes laden with contaminates and is unable to properly lubricate the engine. This increases friction and wear.
There are a number of methods for evaluating the condition of your engine. A compression test can reveal the condition of your pistons, piston rings, cylinder bores, head gasket(s), valves and valve seats.
An oil pressure test can warn you of possible engine bearing, or oil pump failures. Excessive oil consumption, evidence of oil in the engine air intake area and/or bluish smoke from the tailpipe may indicate worn piston rings, worn valve guides and/or valve seals.
As a general rule, an engine that uses no more than one quart of oil every 1000 miles is in good condition. Engines that use one quart of oil or more in less than 1000 miles should first be checked for oil leaks. If any oil leaks are present, have them fixed before determining how much oil is consumed by the engine, especially if blue smoke is not visible at the tailpipe.Compression Test
A noticeable lack of engine power, excessive oil consumption and/or poor fuel mileage measured over an extended period are all indicators of internal engine wear. Worn piston rings, scored or worn cylinder bores, blown head gaskets, sticking or burnt valves, and worn valve seats are all possible culprits. A check of each cylinder's compression will help locate the problem.
- Make sure that the proper amount and viscosity of engine oil is in the crankcase, then ensure the battery is fully charged.
- Warm-up the engine to normal operating temperature, then shut the engine OFF .
- Disable the ignition system.
- Label and disconnect all of the spark plug wires from the plugs.
- Thoroughly clean the cylinder head area around the spark plug ports, then remove the spark plugs.
- Set the throttle plate to the fully open (wide-open throttle) position. You can block the accelerator linkage open for this, or you can have an assistant fully depress the accelerator pedal.
- Install a screw-in type compression gauge into the No. 1 spark plug hole until the fitting is snug.
- According to the tool manufacturer's instructions, connect a remote starting switch to the starting circuit.
- With the ignition switch in the OFF position, use the remote starting switch to crank the engine through at least five compression strokes (approximately 5 seconds of cranking) and record the highest reading on the gauge.
- Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes and/or time as the first.
- Compare the highest readings from each cylinder to that of the others. The indicated compression pressures are considered within specifications if the lowest reading cylinder is within 75 percent of the pressure recorded for the highest reading cylinder. For example, if your highest reading cylinder pressure was 150 psi (1034 kPa), then 75 percent of that would be 113 psi (779 kPa). So the lowest reading cylinder should be no less than 113 psi (779 kPa).
- If a cylinder exhibits an unusual