Rookie rebuild of a 3.0
 

I finally finished my first rebuild, or perhaps refresh is a better term. I thought I'd post this up as encouragement for anyone who is on the fence of trying it for the first time. I think i spent as much time reading Wayne's book and the wealth of knowledge here on PP, as I did actually working on it. Huge thanks to those who answered my questions and regularly share their expertise with us.

What I learned...patience...take LOTS of pictures...bag and label everything...don't skimp on tools; buy, borrow or rent the right ones for the job...put your tools back where they belong after you use them or you will waste a lot of time walking in circles looking for them...tearing down is fun, cleaning sucks, putting back together is tedious but very rewarding...don't let your over-tightening buddy put your fuel pump back in or you'll have a major fuel leak and have to wait for a new pump to arrive before the glory of the first start :mad:

My goals for this 105k mile engine were simple...stop the waterfall of oil leaks...eliminate smoking exhaust...replace any worn parts.

Here we go, she's out
http://forums.pelicanparts.com/uploa...1374297888.jpg

Had to do it
http://forums.pelicanparts.com/uploa...1374298050.jpg

CIS off...yuck
http://forums.pelicanparts.com/uploa...1374298101.jpg

Look familiar?
http://forums.pelicanparts.com/uploa...1374298148.jpg

More yuck
http://forums.pelicanparts.com/uploa...1374298195.jpg

Broken head stud, of course.
http://forums.pelicanparts.com/uploa...1374298246.jpg

I took this one to remind myself of where I measured the sprocket height from
http://forums.pelicanparts.com/uploa...1374298316.jpg

This one to remind me which direction the rocker bolts were in
http://forums.pelicanparts.com/uploa...1374298358.jpg

Speaking of the right tools...I thought I was pretty creative fashioning this large c-clamp into a valve spring compressor. After 2 valves I bought a real OHV tool. That turned aggravation into seconds per valve to remove and reinstall.
http://forums.pelicanparts.com/uploa...1374298798.jpg

to be continued...

To remove the guides, I tapped the top end, inserted an M10 and they came right out with an air hammer. I believe that tip came from Henry.
http://forums.pelicanparts.com/uploa...1374299062.jpg

Valves before and after. Permatex gasket remover and a scotchbrite do wonders on carbon.
http://forums.pelicanparts.com/uploa...1374299134.jpg

IMS bearings were shot, mains looked great
http://forums.pelicanparts.com/uploa...1374299193.jpg

Fast forward...crank, rods, cams, p&c all checked out...let's start putting it back together
http://forums.pelicanparts.com/uploa...1374299314.jpg

Hardware lined up for the 574 race that everyone is paranoid about, but turns out to be no big deal.
http://forums.pelicanparts.com/uploa...1374299369.jpg

It started getting exciting at this point
http://forums.pelicanparts.com/uploa...1374299534.jpg

New steel lower studs all around
http://forums.pelicanparts.com/uploa...1374299577.jpg

Starting to look like an engine
http://forums.pelicanparts.com/uploa...1374299634.jpg

Cam timing was much easier than I thought it would be
http://forums.pelicanparts.com/uploa...1374299751.jpg

Ta-da!
http://forums.pelicanparts.com/uploa...1374299787.jpg

Time for the moment of truth. After a few minutes to burn off the oil I primed the cylinders with, the 20 minute run in was smoke (and drama) free. :D

<iframe width="560" height="315" src="//www.youtube.com/embed/SO6ZISRvLu4" frameborder="0" allowfullscreen></iframe>
http://youtu.be/SO6ZISRvLu4

There seems to be an awfully noisy exhaust valve on the driver side. The break in oil is out and I'll readjust them before the on-road break in. Other than that, the engine ran silky smooth.

The oil filter looked good
http://forums.pelicanparts.com/uploa...1374300238.jpg

And....drum roll please.....no leaks!!!

http://forums.pelicanparts.com/uploa...1374300266.jpg

That's my tale. I have to finish up my CV repacking, bleed the brakes one more time after having rebuilt all four calipers, and I'll be able to get it out on the road for some more break in. Fun stuff.

Nice work!

Awesome work - well done! Thanks for sharing,

Was there any damage to the heads and/or cylinders from broken lower studs? If so, how did you deal with it? Thanks,

Fortunately there were only two broken studs and they were not on the same cylinder. The mating surfaces showed no signs of damage.

Nice work - congrats! Nothing like that first startup...

GK

Goodgame man ! Do you powder coated you fan ?

I did not powder coat. I used a high temp auto enamel. Powder coating is certainly more durable, but it looks good for now.

Nice job.
Great to see/hear it running again, and leak free too!!
Way to go.