Engine Overhaul Kama 554

[Red55]

After writing down all those details, I finally lifted the crank out.
Shees, it was heavier than I thought. . . . I wore my best flannel for that picture.



Loretta and I spent the rest of the day removing old torn gaskets.
Tomorrow we'll start cutting out new ones. When the new rod bearings arrive, I can install them and the main bearings.

Glad to see the show's Producer(s) are taking care of your wardrobe! -Ed

 

[SPIKER]

I had not seen thrust washers like that myself

The crank looks a little scored as does the old bearings...

Mark

 

[Rich Waugh]

Nice shirt, Rob! And still clean, too.

Uhhhhh...do you have a separate bag of clubs for every hole you play, or every course, or just every day of the week and twice on weekends? **** - I managed to get by with just one bag of clubs for years. Maybe that's why my handicap was in three digits, huh?

Rich

 

[3RRL]

Got a little more progress today.
I did manage to get those thrust washers going the right directions. I didn't take any photos, but Loretta and I got the new crankshaft installed ... sitting on the new main bearings in the block. I had to play golf today, so I didn't get much else done on the engine. Tomorrow I'll torque up the mains and rod caps and see if the crank still turns freely. Then finish up making the rest of the gaskets for further assembly.
Thanks for all the comments guys.

Rich, about those bags in the background...
Yeah, I used to play a little before I moved up here. Some are just old sets of clubs (and bags) that I've collected over the years. I play with one set now ... mostly hybrids. There was a time where I played at scratch for many years. Even thought about trying the senior tour, but that went out the door when I managed to get into a pretty good crash on my Harley. Now I just play on Fridays with a group of other old dudes.

 

[dfkrug]

Not only that, but every gasket is destroyed so you have to make or buy a new one every time.
Your suggestion would save a lot of time and effort for future endeavors.

Anybody have other suggestions about that?

I use silicone RTV for most things now. Years ago, I met a racing exhaust
system fabricator and he said you should go to the hi temp RTV for even
the exhaust manifolds. I have run into only a few cases where the extra
thickness of a gasket was necessary to avoid interference.

I think that RTV sealants are not used too often on assembly lines because
it takes longer to apply.

 

[Willl]

What are you using for assembly lube ?

 

[3RRL]

What are you using for assembly lube ?

I'm using my motor oil ... 15w/40 Delvac 1300.

 

[3RRL]

Loretta spent a great deal of time helping me clean off the parts and making new gaskets.



We used 1/64" thick general purpose gasket material for the front and rear and main oil sump.
The oil pump used 1/32" thick material and the oil pan has a new rubber gasket. Below are photos of gasket making. Some of you might do it differently, but this is how we did it. We traced around the perimeter and cut out using either scissors or a razor blade (or both). Then for clearance holes, we used a large ball bearing and pushed it into the screw clearance hole. Then tapped it with a hammer to outline or punch out the hole. The line up of holes turns out excellent using that method.
Here are some of the gaskets made that way.

 

[3RRL]

In that third photo above, you might have seen the new rubber gasket for the oil pan?
We again traced the outline and cut that out first. We also traced each hole with a maker. Then we used a set of hole punches from Harbor Freight and a hammer to punch in the holes. Then cut the middle out, leaving about 1" wide gasket.



While Loretta was busy doing that, installed the new oil pump.
I had to prime the pump before I installed it by pouring oil into the intake tube. I used a drill motor to spin the shaft to see the oil working it's way through. After that, a new pilot gear and 12 x 40mm dowel into the flywheel end of the crankshaft. When she had the bottom end gaskets completed, I was able to button up the entire bottom half of the engine.

 

[3RRL]

Once the bottom half was done, we spun the engine upright.
Next was to install the gear housing (with new gasket) and the injector pump and cam shaft gear. I lined each gear up so the idler gear and others all fell exactly to the teeth that were marked before dis-assembly. I installed the front front pulley, and then the alternator and also a new fan belt. Finally installed the power steering hydraulic pump and connected up the fuel injector pump lines.
Here's what it looks like now.