CHAPTER 2
PREPARATION AND REMOVAL
Before getting started, I’d like to quote a simple statement that, in my experience, will make this and any other automotive job an easier, more pleasant, and rewarding undertaking for you: “Plan your work and work your plan.”
When deciding your degree of involvement in your engine rebuild, consider two things: first, the time and expense of having someone else perform all the work and, second, the satisfaction of being directly responsible for a job well done. A word of caution here: While I’m as entertained as the next red-blooded American male by Hollywood’s rendition of engine rebuilding and automotive restoration, there is little resemblance between what you see on the flat screen and what awaits you out in the garage. In the real world, the task of removing, rebuilding, and replacing the engine in your car or truck cannot be accomplished in an hour and will result in you getting a tad dirtier and being a bit more challenged than the guys on your favorite automotive show.
Engines are rebuilt for various reasons, ranging from noticeable loss of power and efficiency due to high mileage (just plain worn out), to the quest for more power (you want to go faster). In a worst-case scenario, a rebuild may be necessary due to failure of internal engine components (you don’t have much choice). Whatever the reason, you have decided to proceed with removing and rebuilding your engine. But before the first wrench is turned or the first knuckle skinned, there are questions to be answered and logistics to be arranged.
It’s not a pretty sight, but that shaker scoop atop the air cleaner on this engine indicates that something special might be below. Not only does the shaker rest on a 429 Cobra Jet engine, but the engine sits between the fenders of one of just a handful of specially built 1970 Torino NASCAR pace cars. This engine rebuild will be part of a total restoration of this rare car belonging to Mike Parrotta of Columbus, New Jersey.
First, to what level do you want to take this rebuild? Keep in mind that there are various types or levels of rebuild from just freshening it up with new piston rings and bearings throughout to the modifications required for all-out competition.
The purpose of this book is to cover all aspects of an engine rebuild, focusing on stock but also featuring high-performance modifications. The term “stock rebuild” refers to restoring the engine to factory specifications using new original or correct replacement components in order to restore power and efficiency.
The next level on the rebuild continuum consists of internal modifications that allow the engine to retain a factory appearance while providing improvements in performance and reliability.
Last but not least is the dedicated performance buildup that not only includes aftermarket internal parts and modifications but also external changes from oil pan to air cleaner.
The logistics and the support required to successfully complete the project are also important considerations in any engine rebuild project. So let’s get started planning our work in order to work our plan.
Research
Know your subject, read, and ask questions. By reading this book in advance of beginning your rebuild, you will gain insight into the task at hand, know what steps to follow, the tools and services that will be required, and recognize the differences between the Lima series engines and others.
Facilities
While accomplishing a successful rebuild relying on a handy tree limb for a hoist and the dirt floor of an old chicken coop for an assembly room is probably stretching it, many fine running engines, including some used in all-out competition, have been assembled in the home shop. Experience has taught me that a clean, well-lit workplace is of the utmost importance when assembling an engine. And the degree to which you choose to outfit your home shop will directly affect the ease with which the task at hand will be accomplished. But keep in mind that a garage full of woodworking tools won’t take you too far in automotive applications.
Tools Required
The phrase “may be installed with common hand tools,” is routinely encountered in the directions that accompany parts (and yes, it’s probably a good idea to read them before proceeding). Suffice it to say that a home shop that is well stocked with high-quality hand tools is a great place to start when rebuilding an engine. When I say quality tools, I’m not advocating you flag down the nearest Snap-On truck and hand over your credit card, but by the same token, the tools in the 99-cent bin at your local home-improvement emporium are definitely not a good choice. Over the years I have had great luck with Craftsman tools, and in terms of quality for the price and availability they can’t be beat.
I recommend buying a good floor jack and jack stands, as they are not only necessary for the task at hand but will ultimately prove useful for a great many home auto repairs. And while a hoist, engine stand, and certain other specialized tools will be required for your rebuild, it isn’t always necessary to purchase them outright. Many auto parts stores will rent you what you need and, of course, being acquainted with someone who has a well-equipped home shop doesn’t hurt either. You should have at your disposal complete sets of ratchets, extensions and sockets, both standard and deep, in 3/8- and 1/2-inch drive; a quality torque wrench; a full assortment of screwdrivers, hex tools, punches, and drifts; and combination wrenches in sizes from 1/4- to 1¼-inch at the very least. Hammers of various types and a pry bar or two will come in very handy as well. Also, the luxury of an air compressor and pneumatic tools will make the job easier and quicker to accomplish.
There are some special tools that aren’t very expensive and will be very helpful during the rebuild, and therefore should be considered for purchase. Simple tools such as a ring compressor, ring filer, ring expander, vacuum gauge, timing light, remote starter switch (especially handy for vintage Fords like ours), and others will not only make the job easier but will be handy to have for future rebuilds as well.
If your garage has the luxury of an air compressor, congratulations, as this will allow the use of air tools. Fear not, you can still accomplish most automotive tasks without air tools, it will just require a little more muscle power.
Important!
Think safety! Having a fire extinguisher handy when working with flammable materials is always a good idea. And don’t wait until you are faced with a need for the extinguisher to read the operating instructions. The extinguishers state of charge should also be noted periodically.
Sockets, both standard and deep-well, along with various hex ends are a must when rebuilding your engine.
A set of line wrenches will save valuable fuel and air-conditioning lines from damage during removal.
This type of puller is necessary to remove the vibration damper from your engine. Do not attempt to force the damper off by other means, as serious damage may occur.
Several types and sizes of hammers may be required to coax parts that have been in place and exposed to the elements for many