NJACE Tech Session - Engine Rebuild - Day 1 of 2.

In 2011, we built a spare engine for Ken Schifftner's Corvair. Here are photos from the second day's work - December 3.

Click on any of the thumbnails to see the full-size photo.

092_oil_pump_clearance_1.JPG
Brian O'Neill checking oil pump gear clearance with a feeler gage.
096_oil_pump_cover_gasket.JPG
Clearance is determined by the thickness of the gasket for the oil pump cover.
097_oil_pump_cover_bolts.JPG
Driving home the oil pump cover bolts
098_torqueing_oil_pump_cover_bolts.JPG
And finishing the job with a torque wrench.
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When in doubt, lookup the torque specs in the Corvair shop manual.
100_checking_ring_gap.JPG
Checking ring gap in the cylinders before installing the rings on the pistons.
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Brian installs the rings onto the pistons by hand.
103_installing_rings_with_tool.JPG
Ken Schifftner prefers to install the rings with a special tool.
104_aligning_ring_gaps_1.JPG
Al Lacki attempts to align the ring gaps so they are on opposite sides of the piston.
106_aligning_ring_gaps_3.JPG
Brian inspects Lacki's work to ensure the ring gaps are properly aligned.
107_installing_jugs.JPG
Installing one of the cylinder jugs on the crankcase.
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Oops! We need to remove the top cover to install the rod caps!
109_crankcase_access.JPG
Access to the rod cap nuts is through the top cover. Tight!
110_lubing_the_journals.JPG
Lubing the journals before installing the rod caps.
111_six_jugs_installed.JPG
All six cylinders finally installed.
112_reinstalling_top_cover.JPG
Reinstalling the top cover, after installing the rod caps.
113_tightening_top_cover_bolts.JPG
Installing the top cover. Be sure to include the tin baffles and gaskets inside!
114_torqueing_top_cover_bolts.JPG
Torquing the top cover bolts.
115_lasagna_tin_installed.JPG
Lasagna-shaped air-baffles are installed with snap clips.
116_head_gasket_anti_sieze_1.JPG
Smearing anti-seize on head gaskets and head gasket surfaces.
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Fitting one of the two cylinder heads over the head studs.
119_aligning_head_studs.JPG
Sometimes, the head studs need persuasion to align with the holes in the heads.
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Pushing the head home.
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Getting ready to install head nuts.
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First head nut gets screwed on. A combination of nuts and rocker arm studs keep the heads in place.
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Al Lacki assembles the rocker arm studs onto push rod guide plates. A Viton o-ring goes on the back end.
124_installing_rocker_arm_studs.JPG
Joe uses a nut driver to snug down the rocker arm studs and head nuts.
126_lubing_rocker_arm_balls.JPG
Lubing the rocker arm balls.
127_torqueing_rocker_arm_studs.JPG
Torquing the rocker arm studs.
128_torqueing_cylinder_head_bolts.JPG
Torquing the head nuts. Rocker arm studs & head nuts must be torqued in steps & proper sequence.
129_installing_valve_cover.JPG
Easy job! Installing a valve cover!
130_moving_the_engine.JPG
Several guys moved the engine to the floor.
131_aligning__flywheel_holes.JPG
Ken Schifftner aligns the flywheel bolt holes to match the holes on the end of the crank.
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Ken Schifftner installing the flywheel bolts.
133_torqueing_flywheel_bolts.JPG
Out comes the torque wrench again!
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Installing the dummy input shaft.
137_installing_pressure_plate.JPG
And installing the pressure plate.

Corvair - The most innovative cars and trucks ever produced in America!


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edited by redbat01@verizon.net on 10/17/2014