Engines: Engine Rebuilding

Introduction to engine rebuilding	Engine rebuilding introduction	Although every vehicle and engine combination is different in detail, there are fundamental similarities between all internal combustion engines. The methods used to rebuild all types of engines are also very similar.
	Engine removal preparation & safety	Raise the vehicle on jack stands or ramps in preparation to remove the engine.

Removing the engine	Topside engine disconnection	Label, disconnect and organize topside engine components.
	Front accessories disconnection	Disconnect and remove the radiator and any accessories required to remove the engine.
	Underside engine disconnection	Disconnect and remove underside engine connections and components.
	Remove the engine	Remove the engine from the vehicle body.

Engine disassembly	Remove centerbolt & flywheel	Remove the centrebolt and flywheel and mount the engine in a stand.
	Drain engine fluids	Drain engine fluids and remove oil filter.
	Remove front peripherals	Remove belts, accessories, water and fuel pumps.
	Remove side & top peripherals	Remove engine side and top peripherals.
	Disassemble valve train	Disassemble and remove the valve train.
	Remove cylinder heads	Remove the cylinder heads.
	Remove oil pan & timing set	Remove the oil pan and timing set.
	Disassemble block underside	Disassemble the underside of the block.
	Disassemble pistons	Disassemble the pistons.
	Remove crankshaft	Remove the crankshaft and bearings.
	Remove camshaft	Remove the camshaft and lifters.
	Remove plugs	Remove all engine water jacket and oil gallery plugs and camshaft bearings.
	Remove valve assembly	Remove all head components.

Engine machining	Clean & degrease engine	Clean and degrease the engine.
	Inspect & measure engine	Inspect and measure engine components.
	Machine diagnosis	Identify reasons for machining components.
	Machine cylinder block	Machine the cylinder block to operational condition.
	Machine cylinder heads	Machine cylinder heads to operational condition.
	Machine connecting rods	Machine connecting rods to operational condition.
	Clean pistons and fit new pins	Clean pistons and fit new pins.
	Hone cylinders	Hone the cylinders to operational condition.
	Install piston rings	Install the piston rings.

Engine pre-assembly	Pre-assembly introduction	Undertake final check of components for pre-assembly.
	Test install camshaft	Test install the camshaft.
	Test install crankshaft	Test install the crankshaft.
	Test install timing set	Install the small timing gear.
	Test install pistons	Test install the pistons.
	Test install oil pump	Test install the oil pump and pick up tube.
	Piston to valve clearance check	Check piston to valve clearance.
	Long-block build-up	Build-up the long block.
	Paint the engine	Paint the engine.

Engine final assembly	Fit engine plugs	Fit engine plugs.
	Install camshaft	Install the camshaft.
	Install crankshaft	Install the crankshaft.
	Install timing set	Install the timing set.
	Fit piston rings	Fit piston rings.
	Install pistons	Install the pistons.
	Install timing cover	Install the timing cover.
	Install rear main seal	Install the rear main seal.
	Install oil pump & pan	Install the oil pump and pan.
	Assemble heads	Assemble the heads.
	Install heads	Install the heads onto the block.
	Install valve train	Install the valve train.
	Adjust valve lash	Adjust the valve lash.
	Install intake manifold	Install the intake manifold.
	Install engine externals	Install engine external components.
	Pre-oil engine	Pre-oil the engine.
	Install distributor	Install the distributor.
	Assemble accessories	Assemble the accessories to the engine.

Engine re-installing	Hoist & reconnect the engine	Hoist and reconnect the engine.
	Connect engine peripherals	Connect engine peripherals.

Engine start-up	Pre-start engine check	Conduct the pre-start engine check.
	Camshaft break-in	Conduct camshaft break in procedure.
	Engine timing adjustment	Adjust the engine timing.