T-Bird Car Restoration Project Part 4 - Rebuilding the Engine - Page 2

Once the block and heads were cleaned we applied stripper to take off any residual paint, then wiped down the surfaces with phosphoric acid (metal prep.) The acid dried overnight and we sprayed a coat of self-etching primer to prevent flash-rust and get the pieces ready for painting. We also cleaned and prepared the timing chain cover, intake manifold, water pump and oil gallery cover.

By the time we'd cleaned the assemblies the new parts were delivered. Starting with the block, we proceeded to put the engine together. The first thing, of course, was to thoroughly clean out the cylinders and hone them for the new pistons and rings. After honing we wiped the surfaces clean with several applications of solvent to get rid of any leftover grit. We cleaned the main bearing journals, rod and crank journals and oil galleries the same way. We double-checked the new ring end gap and then sprayed the cylinder walls with fogging oil.

We inserted the rings into the cylinder to check the ring gap.

We assembled the rods onto the new pistons and installed the new rings. After cleaning and inspecting the lifters, camshaft and bearings, we coated the parts with assembly lube and installed them. We did so because access to the parts was far easier without the crank and rods being in the way.

New pistons and rods.

Installing the camshaft...note generous application of assembly lube.

The crankshaft went in next, after coating each main bearing and journal with assembly lube. We carefully torqued all the main bearing caps a little at a time, making sure the crankshaft turned freely as each cap was tightened. Once the caps and end seals were properly tightened, we carefully measured the crankshaft end play. This is a critical dimension, as too little causes leaks and block failure while too much causes main and rod inserts to wear quickly. Next we installed each piston/rod into its proper cylinder. We turned the crankshaft frequently to be certain that nothing was binding.

We put a nice coating of assembly lube on the main bearing caps during assembly.

The sleeve holds the rings in place as we slide the piston in.

With the pistons, crank, camshaft, etc., in their places, we carefully installed the timing chain and sprockets. The Y-Block has a somewhat strange procedure for installing the chain, so we consulted several sources and double-checked the location of the timing marks while counting the number of links of chain between the marks (12). After assuring ourselves everything was correct we installed the cover and its crankshaft seal, then turned our attention to the heads.

We brought the connecting rods to rest on the crankshaft, being careful that we didn't mar the crank surface.

T-Bird Car Restoration Project - Part 4 - Continued on Page 3