By the way, the paint on Koni shocks sucks. As you can see either the varsol or the brake clean removed the yellow from mine. (apparently their primer is good though)

Kirk

I had to work for part of the weekend so not alot got done motor wise.
I got more parts back from the powder coaters. The red parts and the Zinc dichromate. **SHINEY!**

I also received the cat bypass from fabspeed. Also very Shiney.

I put the cylinder air ducts on the engine, and that was about it.

To be honest I decided I needed to install a ceiling fan in the garage because it was too hot in there, and that chewed up half the day.


Kirk
http://forums.pelicanparts.com/uploa...1153791695.jpg http://forums.pelicanparts.com/uploa...1153791715.jpg http://forums.pelicanparts.com/uploa...1153791731.jpg http://forums.pelicanparts.com/uploa...1153791766.jpg http://forums.pelicanparts.com/uploa...1153791781.jpg http://forums.pelicanparts.com/uploa...1153791802.jpg

Nice air mover :)

The parts look great also, who does your powder coating?

I've been very happy with how the parts are turning out. The powder is being done by a local company:

http://www.dicustomcoatings.com/

Small shop that seems to take pride in their work.

Unless work interferes I am hoping to make some real progress this weekend on the assembly.

Kirk

Very nice writeup so far!

-Wayne

Thanx Wayne!

Be sure and yell at me as soon as you catch me making a fatal oopsie!

Kirk

I started off today with picking up a new parts washer (bigger) and a parcel from Purolater with my new intake assembly. (I am replacing the 89 aluminum intakes and throttle body with the later style plastic ones)

Then I cleaned the cam towers and heads for them to go on the engine

After using the new parts washer for 5 minutes I was really kicking myself for struggling with the little benchtop one for the last year.

Kirk
http://forums.pelicanparts.com/uploa...1154162621.jpg http://forums.pelicanparts.com/uploa...1154162654.jpg http://forums.pelicanparts.com/uploa...1154162665.jpg http://forums.pelicanparts.com/uploa...1154162677.jpg

I began by organizing all the parts for assembly of the left side heads and cam towers.

I got the oil drain tubes ready by lubing up the green viton O-rings with dow corning 111. I installed the O-rings on the tubes and put them in place on the block.

Then I wiped down the mating surfaces of the block, heads and cam towers with alchohol, and placed the cylinder sealing rings in place.http://forums.pelicanparts.com/uploa...1154162867.jpg http://forums.pelicanparts.com/uploa...1154162879.jpg http://forums.pelicanparts.com/uploa...1154162888.jpg http://forums.pelicanparts.com/uploa...1154162908.jpg http://forums.pelicanparts.com/uploa...1154162918.jpg

The head stud threads were lubed with optimoly HT and then the heads put in place, with the head stud nuts finger tight.

I used threebond 1104 on the cam tower mating surface, and then put the cam tower in place. (Left side cam tower has a blockoff in place of the hole for the power steering pump)

The oil drain tubes were blocked with some paper towel, and the 18 cam tower nuts & washers were put on, and torqued in sequence.

All new fasteners are being used (Pelican has a complete kit)
http://forums.pelicanparts.com/uploa...1154163051.jpg http://forums.pelicanparts.com/uploa...1154163072.jpg http://forums.pelicanparts.com/uploa...1154163086.jpg http://forums.pelicanparts.com/uploa...1154163104.jpg

After I finished torquing the cam tower to 17 ft lbs in 2 steps I moved on to the head studs.
The head stud nuts were torqued in sequence to 11 ft lbs, and then torqued in sequence + 90 degrees.

Then I put the cam in place and rotated it to check for any problems with binding.

After that I got curious what the valve covers were going to look like so I set them in place. :)

Tomorrow I will do the right side of the engine.


Kirkhttp://forums.pelicanparts.com/uploa...1154163313.jpg http://forums.pelicanparts.com/uploa...1154163334.jpg

Nice road map! And nice valve covers :)

I have a had a setback, but I hope to be where you are in a few weeks. Keep up the great work!

Nice Kirk, I love the parts washer but my cleaning fluid never looks that clean;)

I noticed that when I torque the head stud nuts to 11 ft lbs I have to go back and redo them about 4 times, as soon as I finish the torque pattern, the first ones are back to being finger tight again.

Is this because of the cylinder/head sealing rings crushing?

After about 4 tries of torquing in sequence, they are all at 11 ft/lbs and stay that way, and then I can do the 90 deg.

Has anyone else noted this as well?

Kirk

Mike,

Ya that parts cleaner looked like that for about 30 seconds. :)

Kirk

Setback?
Nothing too serious I hope!

Kirk

I continued today by installing the heads and cam tower on the right side of the engine.
One thing I noted for both sides was that when I torqued the head nuts to 11 ft lbs, by the time I was done all 12, the first ones would be finger tight again. It required about 4 times to get them to a consistent 11 ft lbs. Is this because the sealing ring is crushing?

Kirkhttp://forums.pelicanparts.com/uploa...1154241962.jpg http://forums.pelicanparts.com/uploa...1154241975.jpg http://forums.pelicanparts.com/uploa...1154241995.jpg http://forums.pelicanparts.com/uploa...1154242007.jpg http://forums.pelicanparts.com/uploa...1154242027.jpg http://forums.pelicanparts.com/uploa...1154242042.jpg

I installed the oil pressure reliefs in the bottom and side of the motor, and put in the oil drain plug.

http://forums.pelicanparts.com/uploa...1154242158.jpg http://forums.pelicanparts.com/uploa...1154242173.jpg http://forums.pelicanparts.com/uploa...1154242195.jpg

The left side chain housing was next.

I installed the two left side chain rails first, without tightening their hold down bolts.
Then I put the gasket in with Threebond 1104 on both sides of it, followed by the chain housing.

It took me about an hour to figure out that I was missing the roll pin from the bottom chain rail. If you ever do this, and you buy new chain rails, remember there is probably still some parts stuck to your old chain rails! (buy a couple extra roll pin holders, they crack easily)

The hold down for the rails is irritating because you have to have a very skinny walled socket to fit in the indented holes.

The right side is similar, with the straight rail on top and the curved rail at the bottom. I had the most trouble with the roll pins and their plastic holders. They were stubborn to get in.

I also noticed the powder coater put powder coat on the surface where the oil cross pipes go, so I will have to remove that I think.http://forums.pelicanparts.com/uploa...1154242341.jpg http://forums.pelicanparts.com/uploa...1154242355.jpg http://forums.pelicanparts.com/uploa...1154242369.jpg http://forums.pelicanparts.com/uploa...1154242388.jpg http://forums.pelicanparts.com/uploa...1154242411.jpg

I lubed up the left side cam shaft and installed it. You can tell the left one because the cam lobes look like a V whereas the right side cam has lobes that are more aligned up/down. Then I installed the right cam.

The right side cam shaft also drives the power steering. It is open at the back.

The chain housing to cam tower uses a paper seal, and a green viton O-ring. I used Curil T here for extra sealing.

Then I put in the thrust washer, 3 shims , collar and cam gear on the left side. The cam gear is not bolted down yet.

Similar procedure for the right side, but different number of shims.

(It was getting late atthis point. so I'm a little short of pictures.)

Kirkhttp://forums.pelicanparts.com/uploa...1154242554.jpg http://forums.pelicanparts.com/uploa...1154242577.jpg http://forums.pelicanparts.com/uploa...1154242593.jpg http://forums.pelicanparts.com/uploa...1154242617.jpg http://forums.pelicanparts.com/uploa...1154242632.jpg http://forums.pelicanparts.com/uploa...1154242643.jpg

This morning I checked the parallelity of the cam sprockets. Sorry no pictures, (not enough hands available) basically you hold a straight edge across the motor at the intermediate shaft and measure the distance to the left & right sprocket faces. They were on spec with the factory 3 shims left and 4 shims right.

I installed the oil breather cap with threebond 1211 on both sides of the gasket.

I also installed the oil sensor using a green viton o-ring and some of the misc. hardware on top of the engine.

Then I went to work 'unbolting' ;) the cat from the rest of the exhaust. I think I am going to skip trying to remove the existing O2 sensor. It'll be easier just to buy one.

Kirkhttp://forums.pelicanparts.com/uploa...1154308406.jpg http://forums.pelicanparts.com/uploa...1154308420.jpg http://forums.pelicanparts.com/uploa...1154308435.jpg