Table of Contents
Acknowledgments Introduction Chapter 1: Engine Component Cleaning Airless Shot Blasters Hot Tank Cleaning Jet Spray Cabinets Cold Solvent Wash Ovens Soap and Water Media Blasting Soda Cabinet Blasting Blasting Media Tumbling and Vibratory Cleaning Ultrasonic Cleaning Cleaning with Hand and Power Tools Chapter 2: Precision Measurement Tools MicrometerDial IndicatorDial Bore Gauge Mounting a Bore Gauge with a Setting Fixture Depth Gauge Internal Caliper Gauge Measuring Pushrod Length Valvespring Height Gauge Valveseat Runout Gauge Precision Straightedge Rod Bolt Stretch Gauge Torque-Plus-Angle Ultrasonic Thickness Gauge Torque Wrenches Cam Lobe Checker Chapter 3: Cylinder Block Disassembly and Inspection Step by Step Block Inspection Crankshaft Inspection Rod Inspection Cam Inspection Pushrod Inspection Rocker Arm Inspection Cylinder Head Inspection Chapter 4: Cylinder Block Machining Rough Edge and Obstruction Deburring Main Bore Align Honing Cylinder Boring and Honing Cylinder Sleeving Lifter Bore Honing and Bushings Block Deck Resurfacing Threaded Hole Preparation Block Blueprinting
Chapter 5: Crankshaft Measurement, Grinding and Preparation Measuring the Crankshaft Selecting the Grinding Wheel Dressing the Wheel Straightening the Crank Grinding and Polishing the Journals Grinding the Flywheel Chapter 6: Connecting Rod Inspection and Reconditioning Inspecting Connecting Rods Measuring Rod Bore Diameter Measuring Center-to-Center Length Checking for Bend and Twist Reconditioning Connecting Rods Chapter 7: Pushrods and Lifters Measuring for Pushrod Length Chapter 8: Pistons Measuring Piston Skirts Checking Ring-to-Piston Fit Modifying Domes Checking Valve-to-Piston Clearance File Fitting RingsChapter 9: Cylinder Head Inspection, Service and Machining Resurfacing the Deck Measuring Chamber Volume Installing New Guide Liners Refacing Valves and Seats Measuring Valvespring Height Measuring Valvestem Height Checking Spring Pressure Porting Cylinder Heads Final Assembly Chapter 10: Engine Block CNC Machining Milling the Block CNC Terminology Chapter 11: Port Machining Ports and Runners Verifying and Monitoring with a Flow Bench Port Matching Intake Manifold Plenums Intake Port Surface Extrusion HoningChapter 12: Engine Balancing Out-of-Balance Forces on the Crank Connecting Rods Pistons Engine Styles Bobweights 4-Cylinder Inline Engines Crankshaft Under- versus Over Balancing External versus Internal Balancing Dampeners and Flywheels Chapter 13: Clearance CheckingMain Bearings Rod Bearings Cam Bearings Cam Thrust Piston-to-Wall Clearance Rod Sideplay Lifter Bore Crank-to-Block Clearance Rod-to-Block Clearance Piston Ring Gap Crank Thrust Valve-to-Piston Clearance Chapter 14: Final AssemblyCleaning Cam Upper Main Bearings Crankshaft and Rear Seal Main Caps and Lower Bearings Pistons and Rods Timing Oil Pump and Pickup Lifters Heads Pushrods and Rocker Arms Intake Manifold Distributor Timing Cover, Rear Cover, Oil Pan and Valvecovers Water Pump Crankshaft Balancer
