This is a summary of the steps I followed to overhaul the
Chev 2.5 engine:
- Obtain an engine I bought two engines in pieces for R1000.
- Disassemble sub-assembly and head.
2000-01-17: Stripped block, delivered block and
crankshaft to Inderbore Engineering for measuring.
Got a call from someone wanting to buy the other
block, crank, and one conrod.
2000-01-19: Sold three conrods and pistons for R50. Less
junk in my garage.
Bought new pistons, bearings and gasket set
Delivered head, pistons and cam bearings to Inderbore.
|KolbenSchmidt pistons with rings, 40 thou oversize
|ACL 4cyl con-rod main bearing set, 10 thou oversize
|ACL flanged main bearing set, 10 thou oversize
|ACL cam bearing set (6 cyl, no stock on 4 cyl)
|Payen overhaul gasket set||229.70
2000-01-24: The valves in the head were standard,
so I need first oversize replacements. (Note: On this
engine, they don't fit new valve guides, they ream
out the head and fit valves with a thicker stem. I'm not
sure whether this is a good idea...) The plastic /
phenolic / whatever cam gear bothers me (if it strips in the
middle of nowhere, hooo boy!) but an aluminium
(oops, sorry, chev is an american engine, aluminum :-)
replacement is available.
|Dynagear aluminium camshaft gear
|AE .003" inlet valves
|AE .003" exhaust valves
|Worldwide hydraulic cam followers
- Head, block and cam to engineering shop
(Inderbore, they're good, but not cheap) to:
- Bore block (Get measurement for new pistons).
2000-01-18: The block is worn 25 thou oversize, so
I'll need 40 thou oversize pistons.
- Check crank journals, grind if required (Get
measurement for big end and main bearings).
2000-01-18: Not much damage here, 10 thou oversize
- Check cam journals and lift.
2000-01-24: The cam is OK but I need a new gear.
- Fit new cam bearings.
- Ream valve guides.
2000-01-24: New valves (first oversize, 3 thou) required.
- Fit new valve seats and lap.
2000-01-28: Fetched everything from Inderbore, the
pistons and conrods have to go back
after balancing to shrink-fit the gudgeon pins.
Note: I could have saved about R100 by sourcing and fitting
the welch plugs myself, but when
|Rebore 4 cylinders||180.00
|Shrink fit 4 pistons||98.00
|Fit 3 cam bearings||64.00
|Clean block, head and crank||80.00
|1 set welch plugs (block)||65.00
|Reface 8 seats||60.00
|Ream 8 guides||80.00
|Surface grind head||96.00
|Surface grind block||96.00
|Grind in and assemble (head)||80.00
|Glass bead head||40.00
|1 set welch plugs (head)||48.00
I got the quote I assumed it excluded the welch plugs and it still
sounded reasonable to me, so
in my books I'm ahead.
- Pistons, conrods, crank and flywheel to Finley Turbines
- 2000-01-28: The three holes that hold the Chev
pressure plate to the flywheel line up with
the Land-Rover pressure plate. I had three more holes
drilled and three alignment pins fitted.
|Drill and tap flywheel
- 2000-02-07: Balancing done.
|Balance 4 cyl engine complete
- Adaptor plate
- 2000-02-08: It will be too expensive to modify the
6 cyl adaptor plate, easier to buy a new
one. Moose engineering makes solid steel adaptor plates,
very nice but fairly expensive
(R2500-ish). Gilo Engineering has a foundry and casts aliminium
adaptor plates. Ordered an
adaptor plate and a pilot bearing.
Tip: Use paper towels or toilet paper to clean everything
when assembling an engine. Bits of rag
that stay behind might block an oil passage, the paper towel
bits dissolve in the oil.
|Oil Filter (GUD Z44)
|Plugs (NGK BP5ES)
|Distr. Cap (Echlin RR181)
|Points (Echlin CS788)
|Condensor (Echlin RR175)
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(This page last modified 2002-09-18)