1600cc Engine Build Series - Part 1 - Short Block:

Video Transcript:

hi I'm s jbugs.com and today we're going to get started on building an empty unassembled long 0:09 block so this unassembled long block comes in 1 two 3 four five boxes box one 0:16 of five two of five three of five four of five five of five it just so happens 0:21 that we got this kit back because it's a aluminum case and the case was actually damaged in shipping customer decided 0:28 they didn't want it I don't blame them it's a brand new engine they spent a whole lot of money on it 0:33 but as you can see here we've got this nice chip missing off of this case where it 0:40 was damaged so we brought it back sent them out a new kit and we're going to 0:46 take all these boxes open them all up set them all out here and go through all the parts and pieces and then we'll 0:54 start building this engine oh look at that there's the chunk that was missing Parts breakdown 0:59 and truth be told we also did some work on this test fitting some intake manifolds so it's not normally covered 1:05 in blue tape but it is normally all together they got some 1:13 Molly pistons and cylinders and I guess this is a 1:18 crankshaft and indeed a crankshaft it 1:28 is crankshaft installation kit one of the first couple things we're going to have 1:34 to do is heat this up heat this up so we can install them on our crank dishwashers lock ring 1:42 and distributor drive gear we've got some general Hardware new valve covers 1:50 Bales studs that's a big box for a little 1:55 screen we've got dowel pins distributor Drive 2:00 washers gland nut that should be over there cuz that goes in between those 2:06 guys oil pump cover glan nut washer cylinder deflect 2:15 tin distribute a drive pinion try to make a run for it sump 2:23 plate got some engine case Hardware some studs more studs Crush 2:36 washers uh hex head with/ qu mm 2:41 Drive uh oil relief Springs or oil relief plugs rather and 2:47 stuff like that we got some main bearing dowal pins some valve adjustment studs lifters 2:55 cam bearings flywheel seal rod bearings main bearing oil pump connecting rods 3:02 I'm guessing yep cam shaft is my 3:10 [Applause] guess cam shaft indeed and that looks 3:17 like a fly wheel indeed it is push rod tubes rocker assembly engine 3:25 gasket kit very handy when you're building an engine chali push rods and 3:30 cylinder heads all right so this might seem like Word of advice 3:36 it is a lot of parts and in reality it is but uh if you've built a Lego 3:42 set you can probably build an engine you've just got to follow a couple key 3:48 instructions this video is by no means going to be an end all be all you know watch this and you can do 3:55 anything video this is going to be just a general overview more for entertainment purposes but there will be 4:02 some education along the way you'll get to see how all this stuff goes together uh unlike the last engine build we did 4:09 where I had to do clearancing the case clearancing the rods setting up rocker geometry this is going to be a pretty 4:15 much straight bolted together kit there shouldn't be much modification um or anything fancy needed 4:22 this literally should be just bolted all together we might run into some pitfalls along the way and we're going to show 4:28 you everything that we go through through so you'll have an idea of what you would have to go through at home but 4:33 again this is something that anybody with you know some average mechanical 4:40 experience should be able to do relatively easy there's nothing fancy here there's no you know 4:48 machine work required there really aren't many specialty tools required it's just a simple bolted together kit 4:56 so let's get into that we're going to start by taking these these over to our Parts cleaning 5:01 solvent tank rinsing off some of the debris and we've got some either 5:08 dried up cosmoline or stuff in here but either way we're going to rinse all these things off so that we can go 5:16 through and get our Inplay preset we're going to verify it 5:24 later but for now we're going to bolt these together once they're clean 5:30 all right we're not going to show this step for every single product that we put together but just know that 5:36 virtually every single piece that we bolt on this engine is going to be 5:42 thoroughly cleaned dried main areas we're concerned about 5:49 are obviously the journals where the rods and the main bearings will sit and 5:56 then everything else is just getting it generally clean these cranks are drilled with what's 6:02 called a cross drilled P pattern so the oil pressure comes in and gets pushed everywhere and hit it some hearts 6:09 cleaner but she'll be good to go all right all right uh guess I'll 6:18 take these outside and hose them off all right we got ourselves a nice little uh 6:24 rinsing rinsing station over here apparently I'm go blow these out spray them 6:36 [Music] 6:52 down this step we are going Initial crank end play check (with timing gear prep) 6:58 to temper temporarily install our crank bearing to our 7:06 flywheel and check for endplay saddle bearings these will 7:12 eventually go right there snout bearing will go right there full circle bearing will 7:19 go right there most importantly and what we're setting now is our thrust bearing 7:24 which goes at the back and actually if you look at the surface just happens to 7:29 match up ever so nicely with that diameter right there and that's what we're going to work on right now and you 7:36 know what while we're doing this I might as well get our crank gear 7:42 warmed up this is kind of like planning three steps ahead so to speak this is 7:49 our cam timing gear it's got two notches here these face out but if we look at 7:56 this right now it can not fit onto the 8:03 snout it's got to be heated up same thing with our 8:09 brass distributor drive gear now this guy actually spins that guy with those heel 8:15 C gears same thing and there's no indicator on this but it can't fit on 8:21 either these both have to be warmed up this one goes on first that one goes on second so we're 8:27 going to put that one in bottom that one on top cover them with oil so 8:33 they warm up evenly and generally as soon as this oil 8:38 starts smoking that means that the gears are ready to 8:45 install so hopefully by the time I'm done doing all that those are ready to go and hopefully not sooner not that it 8:51 matters at this point but on all of our main bearing dowels they're always going to point towards the flywheel we'll get 8:57 some of my favorite assembly Lube contains zinc Molly that's the most important 9:07 [Music] part we're just going to tighten this 9:14 guy temporarily so that we can come through 9:21 here and measure how much play we have in that surface right 9:27 there what we want is that much 9:32 play but we need to have that rest that space taken up with 9:38 shims so that the crank doesn't move forward and N that's our end play on our crank 25 and 11 so what we need again is 9:48 4,000 so 25 and 11 gives us 9:55 36 right yeah so 25 and 10:02 11 2511 gives us 36 but we need to have 4,000 so we need to have 10:09 32,000 of shims when we build up our engine so we're going to remember that number 32,000 remember that people 32,000 all 10:18 right we'll get ready to install our gears lots of assembly Lube that main Timing gear installation 10:24 set that bearing or that dowel pin rather needs to be on the side of 10:33 of the flywheel now we need to 10:38 install our timing gear and if we're lucky that won't pop 10:44 out like it did last time but just like last time I'll have a hammer and punch 10:49 ready and I don't have gloves this time so this might be harder than it should 10:55 be woo 11:04 and I don't have gloves and same thing as last 11:13 time hopefully this thing doesn't heat up too much in the 11:23 meantime and dang it I may have screwed this P all left and 11:30 [Music] 11:36 right am I even close nope I'm not even close turn that off unplug 11:42 that we're going to have to do a redo on this but hopefully I have the gear 11:48 puller round two try two first time the gear wasn't hot enough and I 11:54 dropped it now I've got gloves so hopefully 12:00 [Music] you get back out of 12:05 here there we go boom and we've got our notches 12:22 up all right that guy just installs right around 12:27 that and our brass timing 12:32 gear there are no indicators on this thing it's helical so not a big 12:40 deal and just like that let's turn this guy off and unplug 12:48 him remove that and yeah you can see where I spilled and we made lots of 12:55 smoke smells like a state fair in here now though all right snap ring pliers are 13:02 next one of those fancy tools you're going to have to have I'm 13:09 sorry there we go now we've got to get over that 13:16 lip and down to the next section there we go that's one 13:25 side there we go 13:30 boom there we go got it ever so cautious because we don't want to damage the 13:37 brass down below and then that will sit right there after this 13:43 bearing but for now we're going to work on connecting rod connecting rod connecting Connecting rods installation 13:49 rods so let's do that now these guys aren't so filthy as these were so 13:57 I'm just going to hit these these with some brake 14:05 clean just because there is some packing oil in them really important thing to note on stock connecting 14:13 rods one side has a nub raised nub one side 14:20 doesn't this raised nub needs to face up so this one will sit here this one will 14:26 sit here but either case they're both going to be sitting up these two are 14:32 going to be facing this way these two are going to be facing that way so both those cylinders are out at the same time 14:38 while both these cylinders are down and they came with their own specific torque sequence even though it 14:44 doesn't match Volkswagens we're going to follow their 14:49 [Music] sequence now we're going to prep our connecting 14:56 rods and bearings 15:17 [Music] 15:27 keep these guys matched up they are paired 15:32 alike but they do have bearing tangs both those bearing tangs go on the same 15:41 side and like 15:46 so generous amounts of assembly [Music] 15:53 Lube coat all of our journals 16:00 while I'm at it we'll install 16:07 here make sure that your bearing tangs match 16:12 up face to face when you're installing the caps and I didn't check 16:20 that over on this guy but that one's good that one was bad so it's a good 16:26 thing that I checked and I reminded you all and I reminded myself at the same 16:37 [Music] 16:44 time all right everything moves 16:49 smoothly next torque sequence 25 ft lb that's 30 foot- 16:57 lb and everything moves freely Nubs up Nubs 17:04 up freely Nubs up Nubs 17:14 [Music] up that 17:26 yeah dishwasher facing up this we're going to give it a 17:32 full flush on in the parts cleaner in the hose with Engine case prep 17:37 carb cleaner then we'll mount it on our bench stand thing I think I'm going to put the case saers in 17:44 first and then wash it that way any threads or debris or otherwise that we 17:50 push out of the threads once we're pushing everything in all that stuff will be rinsed out once we rinse 17:57 everything out cuz some of these holes in the case savers they 18:04 go all the way through so if that means something can go in this way it can come inside the 18:10 case so yeah let's do that so I've got to install a whole bunch of these 18:21 guys this is just Aviation sealant you could also 18:27 use red 18:34 locktite anything of that 18:42 nature like that and like 18:49 that oh that one's deep studded all right that's going to be a fun one we're 18:54 going to have to use a stud on that 19:07 perfect that's what we're trying to do all right [Music] 19:13 now we can get to cleaning out our engine 19:20 case just lightly tapping it 19:27 out and there's our K tabs this has got one 19:35 two three four dowel pins the opposite side only has one dowel 19:40 pin and also has the oil pickup and the studs are already installed so that's handy that's there that's there oil 19:49 pickup tube pressed in place good there definitely things like that is what we're going to have to 19:54 flush out all these journals make sure that that 20:00 everything is cleaned there's no debris obviously now we've got a little bit of our Aviation sealant in there it's 20:07 better than metal shavings I say inside this bore here and that bore 20:13 there those lifters get oil from this Cam Bearing so 20:19 Journal one of the most important ones is of course our oil pump pickups and 20:24 out inlets and Outlets clean that guy out and since 20:30 this case is aluminum we ain't got to worry about it rusting so that's good but either way 20:36 we're still going to give it a rinse with a hose after all this from our main bearing down to this cam 20:46 journal and one from that one to that one that's all those little ports and 20:52 passages inside the engine are all connected there we go 20:59 so out of the oil cooler we go into bearings can bearing can bearing can 21:06 bearing Inlet from the oil cooler hi sorry oil pressure relief make sure that 21:13 guy's all cleaned 21:19 [Music] 21:26 out don't rust anything you can't confirm 21:32 yourself I mean yeah it had a gasket seemed like it was a good stick but I don't 21:42 care apparently couple things we'll be doing here we've got 21:48 a bane bearing dowels to put in cam bearings 21:54 lifters distributor Drive shims distributor drive gear uh at which 22:02 point should be able to drop our uh crankshaft 22:07 in so let's get to it main bearing 22:17 [Music] dowels got one of our 22:23 two saddle bearings distributor drive 22:30 gear and this is going to install with this small 22:37 C lining up this way so that Groove is going to be offset towards the crank not 22:43 towards the flywheel offset Groove towards the crank straight up and down as we're 22:49 installing it into the engine after I can tell you this it's probably a snug 22:55 fit oh okay good not too 23:00 bad little assembly 23:15 lube and so you want that guy in line with 23:23 the case that way I'm going to pull off our flywheel 23:28 and then we can drop the crank Crankshaft installation 23:34 in this is one but this is three so I need to hold one up when we drop it in 23:39 so it's going to go in this way all right nub nub nub nub this is number one that's 23:47 number two let's do our best to align these bearings since you guys what I see 23:53 what I'm talking about we want these guys that that and that we want all 23:58 those bearings to align up with this pin this pin and this pin once we drop her 24:03 in place am I right or am I 24:09 wrong can't be right and backwards I might be completely bass 24:14 Awards mono and I am yep I'm backwards dagging a 24:23 it where are we 24:30 Are we more lined up now yes 24:38 no I've got everything upside down 24:44 monil all right so I've got my rods on 24:54 backwards oh now I've got to take all of our rods off and and redo all that so 24:59 hold please as we can see here I don't build engines every day so I've got all my rods 180 out so 25:08 I'm going to have to go back and flip this this guy 180 that way this guy 180 25:14 that guy this guy 180 this guy 180 that way I forgot that number three is our offset closest to the flywheel so it 25:23 goes 3 1 4 2 25:28 so anyway I'm going to pull all these up here throw them up here real quick flip 25:33 all my rods around retorque them and then we'll reset and we'll drop our crank in hold 25:56 please now let's try this one more time oh let's make sure our distributor 26:03 Drive gears fully seated 26:10 [Music] and that one's 26:19 good that one's [Music] 26:25 good this guy is being 26:31 stinker there we are just felt it I just felt I hope you saw 26:37 it one final test will be to just temporarily set this guy in 26:45 place with the dabal lube make sure yeah no we're not all in place cuz 26:52 that guy is rocking and if that guy's rocking we're not set 27:04 this is for our cam thrust that's why it's got that face 27:10 right there and this is our back bearing over 27:17 here which gives us better room for our Kim plug here we 27:24 go even if you don't know you can still figure it out and then that will allow that guy to 27:32 sit in there much better 27:38 perfect this is a new case so these are going to 27:44 be relatively tight things will be 27:49 tight not like dropping lifs into a a used magnesium case they just kind of 27:55 fall right in cuz those cases have plenty of miles on them these guys don't 28:02 oh wow no oil no Gunk no grease No Junk just a good old stock cam Camshaft prep 28:11 shaft so we're going to go clean it up real quick just in case and then we're going to put it to 28:24 use so we're going to rotate this Camshaft installation 28:31 guy in place like so a little bit more Luby 28:38 lubs cam feels good doesn't look like it's Case half prep 28:43 jumping say we are good to go there um 28:49 normally we put O-rings on these guys it does not look like there's spots 28:54 for O-rings like we're going to put them 29:05 on one main bearing Dow goes on this side along with this main bearing saddle 29:13 bearing I just redid the rear main seal on it actually had Aviation sealant we 29:21 still got a good amount from the last time we did you put some of that on our lifter BS 29:27 get those guys ready for tap tap tap ring in some new 29:35 lifters two from here let's go through and clean 29:40 up a little bit of oil off of our case halves much as we can 29:48 anyway this will give our sealant a better chance of 29:56 Sealing [Music] 30:01 the same thing over here a little bit easier cuz we ain't got much in our 30:07 way let that sit and tack up for the minute uh did I do this backwards again montal I 30:16 did oh your little knobs my 30:22 knobs cuz that's the bottom huh yep well guess what now I'm going to do 30:27 it on the engine remember I had my rods backwards before well apparently either I put them 30:33 on backwards again or I had them on right the first time either way you guys probably saw 30:40 that the entire time and were sitting there screaming and yelling at me why didn't you tell me I couldn't 30:46 hear you that's why wouldn't have mattered anyway so now I'm going 30:52 to pull these off again 30:58 [Music] 31:04 [Applause] Case half installation 31:16 oh a shuffle pin I didn't realize we had Shuffle 31:22 pins my Shuffle pins 31:28 right there Shuffle pins you don't use O-rings right there and right there so let's get those guys out of the 31:37 way I was wondering what those gr big grooves were in there for I guess now I 31:46 know there we go much 31:51 better every single 32:07 [Music] make sure the case the crank turns 32:12 over which apparently it does 32:20 not which is not good so what happened is the question 32:31 did the main bearing fall out maybe that's my 32:36 guess when I was tapping it around to get 32:42 the shuffle pins in perhaps that main bearing saddle bearing got 32:51 [Music] dislodged 32:59 and again we're locked up dude what the 33:09 bearing's good bearing's good bearing's 33:25 good 33:31 [Music] 33:38 everything's happy still that's good we're getting 33:50 somewhere 33:55 finally 34:07 we still spin you get a washer you get a 34:13 washer you get a washer you get a washer but you don't 34:18 get tightened yet you're going to get a bolt but you three are not going to get tightened 34:25 yet [Music] 34:37 is it Overkill putting Aviation sealing on every single bolt and nut and washer 34:42 yeah but you know what I don't like oil leaks it's a Volkswagen still going to 34:48 leak but whatever at least we gave it our best shot that's 34:54 good that's good that's good 35:03 [Music] not tight Oil pump installation 35:19 [Music] 35:25 yet 35:33 long side points towards the center of the cam so then our pickup side which goes 35:40 to our tube lines up follow that with our drive gear now engaged to our Cam 35:49 and even though there's these little alignment marks on these things they literally mean absolutely 35:55 nothing but we'll still make them line 36:03 up there thin 36:09 coat and hopefully we've got some sealing nuts in there more Aviation sealant in lie 36:17 of sealing nuts and least these have nylocks so 36:23 that'll help seal the threads as well 36:40 crank she still cranks over nicely he doesn't like the way that 36:46 sits D NAB it nice try and there's no point in putting Oil sump plate installation 36:53 sealant on these because we're going to run this thing to a break-in run 37:01 and drain the oil so if it leaks it leaks 37:09 note Supply your own sealing washers for your St 37:16 [Music] 37:25 plate is it going to leak probably but that's one thing this thing 37:31 is missing is apparently seiling washers for the acorn nuts for the sun 37:50 plate and then I'll have to it went out aluminum com 37:55 back [Music] 38:03 so that's going to do it for day one as you can see we've got the engine done uh 38:09 I struggled a little bit and I'm not going to lie uh definitely wasn't on point these are the only instructions I 38:16 had which was basically the endplay sequence without the engine assembled 38:24 and then our torque patterns and torque specs that's all the instructions I had 38:29 I was doing everything off memory but I was on one side of the bench working on 38:34 the crank trying to show you guys the audience how the engine should look so I 38:39 was completely backwards through most of that build uh but anyway it's assembled 38:45 it's done and right now we're working on getting aftermarket engine 10 fit to an 38:50 aftermarket engine case which isn't fun but that'll be in an upcoming video in 38:55 the meantime we hope you guys have enjoyed this next week we'll get the top end put on and I struggle there a little 39:03 bit too but stay tuned 39:15 guys Go Solar