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I took a few weeks off from the Jeep to part because I
needed some machinist work done that took time and part because I needed to avoid Jeep
burn-out. It had gotten to the point where I was dreaming out it.
Turns out the #5 piston could not be saved. The machinist suspected that the impact on the
cylinder wall would crush or "egg shape" the piston. I saw him mic it and it
definitely was crushed enough to require replacing it if the job was to be done right. It
was a job getting the timing sprocket unjammed but it came off with a little grinding and a gear
puller. The cam and sprocket survived but the
woodruff key was destroyed.
In four hours Sunday afternoon I cleaned the block, installed the camshaft, installed the
crankshaft, installed all pistons and connecting rods, installed the front components, set the
timing and installed the right head. I need more gaskets so I can install the
other head and the timing cover. This took me a couple of weeks the first time because I
had to battle the drive gear. I'll need to fix the stripped threads on the timing cover
for the fuel pump before I put that on.
I lost my tube of thread lock so I only finger tightened the connecting rod bolts. I'll
get a replacement tube and give the con-rod bolts a healthy dose of the
anti-rebuild-yet-again compound. Don't let me forget to do this!
I only had three hours last night to work in it but it seemed very productive. I thread locked and torqued the connecting rod bolts, installed the left head, installed the lifters, push rods and rocker arms, mounted the timing cover and installed the fuel pump (it's a pain to install after the engine is in). Next: valve covers and oil pan then I lift the engine to install the flywheel, clutch and bell housing.
Yesterday I installed the valve covers and oil pan cover. I also repainted the engine and clear coated it :) I didn't have time to do anything else. It is now ready to come off the engine stand so I can installed the fly wheel, clutch and bell housing then it is ready to go. I figure about two hours will get the engine installed and another two hooking up components so I am about four hours away from igniting it, again.
The clutch cable on my car broke yesterday so my time on the Jeep was limited to three hours. In that time I moved the engine from the stand to the hoist then installed the flywheel, clutch, pressure plate and bell housing. It took more than an hour to successfully stab the engine into place. Brute force just does not work. The more I try to manhandle the engine the more useless it becomes. The trick to stabbing an engine is to go slow, think about it and make small but precise adjustments then bingo -- it goes in without problem. The motor mounts will tell you how you need to adjust the inclination and direction of the engine. I ran out of time after I got the transmission bolts in. Should have it running soon!
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