How to Build a Combustion Engine

Chevy ZF V8 stock engine ready for installation.

Building your combustion engine can be a daunting task, pretty much like putting together a 1,000-piece jigsaw puzzle all by yourself. However, with some planning, patience and attention to detail, everything will be much easier. But before we begin, make sure all the engine parts are perfectly clean, organized and ready to assemble. Then follow these simple steps and we will have your engine ready to be installed in your vehicle sooner than you thought possible. Let's go.

Things You'll Need

• Engine parts Engine stand Assembly lube Piston ring compressor Wrench set Ratchet and socket set Torque wrench

Instructions

1. Mount the engine block on an engine stand. It will let you rotate the engine as you assemble the different components.

2. Install the core and oil plugs on the block. Coat the core and oil gallery plugs with oil-resistant sealant.

3. Turn the engine block upside down, install half of the main bearings set on the block and apply assembly lube to the bearings. Sit the crankshaft in place on the block and install the other half of the main bearings set on the crankshaft caps. Coat the main bearings on the caps with assembly lube and install the caps. Torque the bolts using a torque wrench (see the Tip section at the bottom of the article for more information).

4. Assemble the piston rings and install the pistons on their respective bores on the block using a ring compressor--the notch on top of the piston should face the front of the engine. Sit the bearings on the connecting rods and rod caps. Coat the bearings with assembly lube and install the caps. Torque the bolts.

5. Install the oil pump assembly, crankshaft sprocket, vibration dumper and water pump using a wrench and ratchet and socket. You may install the oil pan at this point but is better to wait and make sure at the end that everything is in place on the block and properly assembled-depending on your engine model, you may install the water pump at this point or wait until you reach step 7.

6. Assemble the engine head, including camshaft, thrust plate, valves, springs, retainers, seals, rocker arms and lifters. Install the head gasket and assemble the engine head on the block. Make sure to coat the camshaft journals with assembly lube and tighten the head bolts in the sequence and to the torque recommended by the engine manufacturer.

7. Install the seal on the timing chain cover and then install the cover, camshaft and crankshaft sprockets, crankshaft pulley and timing chain or belt.

8. Wrap teflon tape around the oil pressure sending unit threads and install the component in place.

9. Install the flywheel, engine mounts, intake manifold, exhaust manifold and valve cover--some or all of these components may be assembled now or later, depending on how much room you have to play with in the engine compartment during engine installation.

Tips & Warnings

• Every engine manufacturer has its own set of bolt tightening sequence and torque specifications for every component during assembly. It is very important that you follow these recommendations to ensure proper engine life and service. You can find these specifications in the vehicle service manual that you can buy at most auto parts stores or consult one at your local public library.