Special Tools and Easy Assembly Sequence

[Terry Burtz, Calif]

My son Jesse and I developed an easy assembly sequence that uses 5 special tools to simplify engine assembly. Although the tools and assembly sequence were developed for the "New Engine", many tools can be used to simplify the assembly of an original engine.

The special tools include 8 valve tools that hold the valves open

An O-ring tool that has an internal taper to compress the O-ring used on a main bearing stud

A dowel tool that holds the crankshaft dowel pin perpendicular to get it started

A seal tool that drives the rear main seal evenly and to the correct depth

An 11/16 inch, 3/8 drive impact socket modified with a slot for a cotter pin

My son Jesse makes 4 of the special tools from PETG, a structural plastic, but does not make the modified socket. The cost for 11 tools is $40, and Jesse's email is [email protected]

The easy assembly sequence is below, followed by pictures of the tools
1) Install all valve guides, springs, valves, and keepers
2) Install all 8-valve tools to keep the valves open
3) Adjust all tappets to be 2.50 inches long
4) Install the tappets, camshaft, and camshaft nut (without camshaft gear)
5) Remove/reinstall the valve tools one at a time while adjusting the tappets
6) Insert the long studs, assemble the O-ring tool, and install the O-ring
7) Push the long stud down to allow the O-ring tool to compress the O-ring
8) Remove the O-ring tool and assemble the castellated nut and cotter pin
9) Assemble the bearing inserts and install the crankshaft
10) Tighten the 12-point nuts on the long studs using the castellated nut socket to prevent the castellated nut from turning
11) Assemble the pistons, rings, and connecting rods
12) Remove the camshaft nut and install the camshaft timing gear
13) Remove the 8 valve tools
14) Install the rear main seal with the seal tool, and crankshaft dowels with the dowel tool
15) Crankshaft torque should be 5 lb-in (piston up), and 25 lb-ft (piston mid stroke)