Many rebuild jobs (crankshafts, bearings, piston rods, and other replaceable components) are well within the capabilities of most car enthusiasts. Patience, the right tools, and common sense along with a basic understanding of engines can yield owner satisfaction and real economic results.
Instrumentation
The tools required to overhaul an engine or replace parts will depend on the depth of your involvement. With few exceptions, these can be found in a mechanic's tool kit (see Chapter 1). More in-depth work will require some or all of the following:
- A circular indicator (reading in thousandths of a centimeter) mounted on a universal base. The base may not be supplied with a new instrument;
- Micrometers and telescopic gauges;
- Pliers, stopper, etc.;
- Gasket scraper; the best one is wooden or plastic;
- Valve Spring Compressor Remover;
- Ring groove cleaner;
- Ring expander and compressor;
- Reamer for cutting off growths;
- Honing head;
- Plasti-gauge bearing clearance measuring tool;
- Engine Stand. This single tool may be the most expensive piece of equipment in your garage, but it's worth it. The engine can be bolted to the stand and then rotated to any position for high-end or low-end operation.
- Winch or crane. The use of most of these tools is illustrated in this Chapter.
Verification methods
Procedures and specifications are given in this Chapter for inspecting, cleaning, and determining wear limits on most large assemblies. Other procedures such as MagnaFlux and Zyglo can be used to detect defects and cracks caused by overstress. Magnaflux is a magnetic process applicable only to ferrous (iron and steel) materials. The Zyglo process is a coating of the material with a fluorescent, dye-like, penetrating liquid and can be used on any material. Inspection of suspected surface cracks can be easily accomplished using a spot test, dyeing. The dye is sprayed on the suspected area, wiped off, and the area treated with developer. Cracks should be clearly visible.
Major Renovation Tips
Aluminum has become extremely popular for use in engines due to its low weight. Observe the following precautions when handling aluminum parts:
- Never treat aluminum parts with hot solution (caustic hot solution will corrode aluminum);
- Remove all aluminum parts (label, etc.) from engine parts before filling tank;
- Always coat the threads with a light coat of motor oil or anti-seize compound before installation to prevent seizing.
- Never overtighten bolts or spark plugs, especially those with aluminum threads.
Worn threads in any component can be restored by using some repair kits.
During assembly, the rubbing surfaces of the engine parts must be lubricated to ensure lubrication during initial start-up (motor oil is not recommended for this purpose).