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Do it yerself engine build (Final update on how it works.)

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Offline zaggy

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Do it yerself engine build (Final update on how it works.)
« on: June 21, 2005, 08:57:25 AM »
Ok guys

 Ã‚    I posted under how much power to see who was interested in an engine build up, well I got 200 hits in 24 hours so I guess theres lots of guys interested so.....

 Ã‚    A little about me....I own my own new and used auto parts company that specializes in Import cars/trucks. I have been in the automotive business about 25 years and working on engines since I was a kid. Over the years I've raced in just about every form of 4 wheel sport except off road including..
- Road Race from 850cc sports cars to 5.0L GT cars
- Auto Slalom Solo 1 and 2
- Stock Cars from Mini Stock to late model
- Sprint Cars
- Drag Race from Cutlass 455 to 13 sec 240Z
- Rally
By the way I've always built my own engines
 Ã‚    I am also a pilot, got my first licence when I was 14 and I'm still going. Been experimenting with Suzuki engines since 1990 and the last one was the 5th in a series that is now residing on my airplane, soon to start flight testing. I've built 1.3/8v's, 1.3/16v's and the 1.6/8v's and done a pile of testing. If you want to view the work look at "pics of zaggy's engine" on the forum.

Zag

« Last Edit: August 25, 2005, 07:29:46 AM by zaggy »
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92 Sidekick 4dr, Suzuki Powered Airplane
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Offline zaggy

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Re: Do it yerself engine build
« Reply #1 on: June 21, 2005, 09:04:12 AM »
Here's the rules I'm setting on the build up.....

1) I will post all the parts prices for what I sell them for,
   no games.
2) All machine work will be done and prices posted
3) I'm not going to mention the name of my company,
   if you want that you can pm me.
4) I will list where I get any parts that I out source, how
   much they cost and if the service was positive or
   negative. (politely I might add)
4) I will list all the tools and resources you will need and
   what I use
5) I will post as many pics as I can, as soon as I figure
   out how.
6) I will answer every question I can and explain
   everything to the best of my ability.
7) I will take every recommendation, suggestion you would like to give.

8) You are the final authority I am giving voluntary
   advice, refer to your manual or local mechanic for
   professional advice. I assume no liability for you
   following along.

         Now lets have some fun.......

The goal....
   We are going to build a 1.6/8v that should produce about 90hp. I'm going to do it as inexpensively as possible but I will not cut corners. This will take a while so keep following.

Zag
« Last Edit: June 21, 2005, 09:19:24 AM by zaggy »
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Offline zaggy

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Re: Do it yerself engine build
« Reply #2 on: June 21, 2005, 09:13:31 AM »
The engine.......

- 1990 Chevy Tracker 1.6/8v
  This engine came out of a salvage vehicle, while it
  was lower mileage the fellow who owned it fancied
  himself a mechanic and incorrectly installed the oil
  pump and siezed the engine.

You will need:
- Something similar to start with, if you can find a runner
 it's better.
- A decent overhaul manual, I use Haynes
- Full set of metric hand tools, sockets wrenches etc.
- Good torque wrench
- Good set of feeler guages
- I recommend an engine stand even a cheap one.
- Decent work bench that is CLEAN.
- Lots of little cans and containers to label and keep
 parts in.
- Masking tape to label containers and parts.
- A place to wash parts in solevent (be enviromentally
 clean).

Now I need to finish getting the shop ready and order parts. I will post again later.

Zag
« Last Edit: June 21, 2005, 09:44:32 AM by zaggy »
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Offline explosivo

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Re: Do it yerself engine build
« Reply #3 on: June 21, 2005, 09:18:55 AM »
Sweet! This sounds like a really kickass thread.

As far as posting pics, once you have them on your computer, go here, upload and post :)
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"Its a ZUKI thing. Doing more with less than less with more." -- HotRod
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Offline Digger

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Re: Do it yerself engine build
« Reply #4 on: June 21, 2005, 10:12:33 AM »
and if for whatever reason that doesn't work for the pics, I can host them for you on my picturetrail account. Let me know, this sounds like an awesome build-up! ;D
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Had a cool sig pic till I changed the text... sigh...
90 Tracker: "Silver", 2" BL, 1-1/2" Coil Spacers, Strut mount flip, Calmini Header, Winch, 31" Swamper radials, Sold.
98 Suzuki X-90: Calmini 2" Sus, 1-1/4" whl spcrs, 2" Exhaust, Cobra Safari Bar, Neon, Sold.
96 Suzuki X-90: Mostly stock daily driver(for now)
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Offline chet

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Re: Do it yerself engine build
« Reply #5 on: June 21, 2005, 10:55:00 AM »
I thin once this thread is done it needs to be an article on ZW. That way it won't get lost in a board crash or something!!

Thanks for this Zaggy!
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Offline zaggy

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Re: Do it yerself engine build
« Reply #6 on: June 21, 2005, 11:23:34 AM »





- Top photo is my work area, notice clean neat and lots
 of small containers to keep parts as they come off
- Middle photo is my tool box, again clean neat
 organized
- Last but not least, our intended victim

The balance of tonight I will dissassemble the engine and start measuring, in spite of my lousy photo skills I will get some pics.

Zag
« Last Edit: June 21, 2005, 11:26:05 AM by zaggy »
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Offline zaggy

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Re: Do it yerself engine build
« Reply #7 on: June 21, 2005, 11:34:06 AM »
Now everything is ready

- Get the engine on the stand, drain it and clean the livin
  tar out of it. For initial clean up I like to use the
 cheapest spray on oven cleaner I can find and the
 shop pressure washer. Then scrub with a coarse brush
 and repeat till it's good and clean. Follow the cleaners
 safety directions.
- If you are re using the throttle body and sensors
 remove them first and clean seperately.
- Tag or box everything with where you took it off and
  follow your manual.
- Be sure you do all draining and clean up in an
 enviromentally friendly way.

Zag
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Proud2BCDN

Re: Do it yerself engine build
« Reply #8 on: June 21, 2005, 12:21:35 PM »
Hmmm...I should get in on this...I have 2 1.6 8v's doing a whole lot of nothing right now...thanks Zag
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Offline zaggy

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Re: Do it yerself engine build
« Reply #9 on: June 22, 2005, 02:04:08 AM »
Morning all

    So the engine is on the stand, drained and clean. Tear down time.
    Using your manual as a guide remove the following and be sure to put the nuts and bolts from each in marked containers...
- Clutch press plate
- Clutch disc (mark the side facing the flywheel so you
 know how it goes.)
- Front pulley upper and lower. clutch fan
- Aluminum air intake on TBI unit
- Distributor and housing
- Intake and exhaust manifolds
- Valve cover and oil pan with pick up tube
- Plastic timimg belt cover
    Now I'm real serious about putting all the fasteners in marked containers, the reason is simple (especially if this is your first engine). It's so you know where they go when we start reassembly....I've built many engines but I still do this because I cannot remember everything.
    I also recommend making enough room so you can lay all the parts out as they come off. For the same reasons.
    Also, save all the parts even if you are not going to re use them, theya are great reference if you mark them as they come off. IE the clutch assembly, amrking the face so you know how to put it back on.
    i didn't have to take off the Alternator or starter, you will follow the same pattern, then clean paint and set aside ready to reinstall.

    This afternoon we will remove the head, pics to follow.

Zag
« Last Edit: June 22, 2005, 02:05:42 AM by zaggy »
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Offline zaggy

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Re: Do it yerself engine build
« Reply #10 on: June 23, 2005, 03:14:17 AM »
OK here we go with head removal....

    Following your manual remove the timing belt, tensioner and related items. Lay them out someplace safe so you know how to put it back together.
    Now undo the head bolts in the reverse pattern to the torque sequence. It may be an old wives tail but I have found when I do it this way the head needs less removed to get it square, maybe coincedence? Use a piece or cardboard to push the headbolts thru for storage and number them, don't loose any washers.
    Now tapping gentley with a rubber hammer work the head loosse. It that doesn't work, check you have taken out all the bolts, and keep working at it. If all else fails use your imagination, but don't damage the head!!!
    Once loose carefully lift it off and what you have should look like the picture.





Zag
« Last Edit: June 23, 2005, 03:17:51 AM by zaggy »
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Offline Zukipilot

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Re: Do it yerself engine build
« Reply #11 on: June 23, 2005, 03:19:36 AM »
Good stuff. Now I'll have a guide when I tear apart the 8V that came out of the Kick :)

Zig
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Offline zaggy

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Re: Do it yerself engine build
« Reply #12 on: June 23, 2005, 03:28:09 AM »
 Ã‚    Now remove the manifolds, saving the nut/bolts in one of your containers and mark the container. Again gently tap them off with the rubber hammer. Remove your distributor and the mounting (use the containers again). Loosen all the rocker arm adjusters waaaay back and slide out the camshaft. Be careful, none of this requires huge force and you do not want to mark or damage anything. Wrap the cam in a shop rag and set it aside for later.
    Mark all the rockers using a metal marking pen, I number them with an "I" for intake and a # number for the cylinder they relate to. Remove the rocker shaft screws using THE PROPER SIZE PHILLIPS BIT with an impact driver. Again don't over do it, and save the screws in a marked container. It's now time to remove the rocker shafts. Slide them out carefully and layout the pieces, in order, as they come off. Once out carefully reassemble each shaft in order, wrap them in a shop rag and set them aside.
    I cannot stress enough how important it is to be organized with your tear down. By being careful now and marking and saving everything you get real familiar with the engine, don't loose anything and makes it much easier to put it back together. Be careful now and you will save time and money later.
    Now clean everything throughly, and I mean throughly, when you are done your head should look like the picture (or better, I was getting lazy as it was gettin late).





Zag
« Last Edit: June 23, 2005, 03:30:45 AM by zaggy »
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Offline zaggy

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Re: Do it yerself engine build
« Reply #13 on: June 23, 2005, 03:32:04 AM »
Here I am going to apologize for the lousy photo's. I bought a digital camera to do this project so I'm learning as I go.

Zag

This afternoon the Short Block

« Last Edit: June 23, 2005, 03:34:12 AM by zaggy »
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Offline Cwkick

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Re: Do it yerself engine build
« Reply #14 on: June 23, 2005, 03:36:47 AM »
Quote
Here I am going to apologize for the lousy photo's. I bought a digital camera to do this project so I'm learning as I go.

Zag



Set it to auto?   8)

Cwkick
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