[Alberg30] A message from THE man (re Atomic 4)

[Brian and Elaine Timmins]

Just in case anyone is doing an A4 rebuild and they haven't joined the list
at Moyer's yet, I pass along this info.
----- Original Message -----
From: <mailist at moyermarine.com>
To: <timmins at optonline.net>
Sent: Sunday, March 11, 2001 8:34 AM
Subject: Engine Rebuilding QC Checklist


> Hello everybody,
>
> If you are one of our many customers who is currently rebuilding your
engine
> in your basement, garage, or laundry room, we're hoping that you might
> benefit from using our Engine Rebuilding QC checklist.  We use this
checklist
> so as not to overlook any of the myriad details that are necessary to get
> right, in order to avoid premature failure.  The checklist is the result
of
> over ten years of experience (sometimes costly).
>
> To some, this checklist might be considered proprietary information, since
the
> rebuilding competition is growing within our market place.  However, we
have
> felt from day one of our business that whatever is good for the Atomic 4
is
> good for all of us.  We still feel that way, so please feel free to share
the
> checklist with anyone whom you think might benefit from it (even your
local
> mechanic).
>
> Don
>
>
>
> CHECKLIST OF CRITICAL ITEMS DURING REBUILD
> Universal Atomic 4
>
> ITEMS TO BE CHECKED PRIOR TO ASSEMBLY:
>
> 1)   Check all castings for rust and scale removal.
>
>
> 2)   Check for maximum gap of .005" (total) between head to block,
>       and manifold to block mating surfaces.
>
>
> 3)   Oil passage ways in block thoroughly cleaned.
>
>
> 4)   Oil passage ways in crankshaft thoroughly cleaned.
>
>
> 5)   Cam bearings installed with oil holes aligned with holes in block.
>
>
> 6)   Inspect threads within stud holes in block and dry-run studs
>      to check for fit.  If any studs are quite lose, replace
>      with a 10 mm stud or install a repair bushing.
>
>
> 7)   Inspect inside of thermostat housing for proper configuration.
>
>
> ITEMS TO BE CHECKED PRIOR TO INSTALLING OIL PAN:
>
> 1)   Three oil plugs installed, one at each end of the cam shaft
>      and one directly below the oil pressure regulating valve.
>
>
> 2)   Timing marks on crankshaft and cam shaft gears aligned.
>
>
> 3)   Two set-screws installed to retain idler gear spindle.
>
>
> 4)   Check max. ring end-gap of .018" on at least 2 cylinder bores.
>
>
> 5)   Check max. of .004"  between ring and ring grooves in pistons.
>
>
> 6)   Pistons installed with number one toward flywheel.
>
>
> 7)   Pistons installed with arrows pointing toward reversing gear,
>      or with slots in piston skirts pointing away from cam shaft.
>
>
> 8)   Rods installed with numbers pointing toward cam shaft.
>
>
> 9)   Alignment tabs on rod bearings placed carefully in their
>      respective recesses in rods and rod bearing caps.
>
> 10)   Each rod checked for side play after installing rod bearings.
>
>
> 11)   Oil strainer installed with proper slope along bottom of oil
>       pan, and with some clearance so as to not press on the
>       bottom of oil pan (spring between screen and 1/8" street el
>       should be almost fully compressed).
>
>
> ITEMS TO CHECK BEFORE INSTALLING HEAD:
>
> 1)   Proper roughness on block deck and head mating surface.
>
>       (Scribe lines using an ice pick or similar tool.)
>
> 2)   Seal all studs into block using Lock-Tite.
>
>
> ITEMS TO BE CHECKED BEFORE INSTALLING THE AFT HOUSING:
>
> 1)   Run feeler gauge under oil strainer to be sure that the screen is
>      not pressing on bottom of oil pan (minimum of .005").
>
>
> 2)   Install small pilot bearing in rear of crankshaft.
>
>
> 3)   Check that idler gear is installed properly and that a cotter pin
>      is installed in the castle nut on early model engines.
>
>
> 4)   Clean oil collection groove and return holes in flywheel housing.
>
>
>
> CHECKLIST OF FINISHING/DETAILING STANDARDS
>
> 1)   All studs extending through head nuts the same distance.
>
>
> 2)   Use standard length bolts on the following assemblies:
>
>      Oil pan                      5/16" x 7/8"
>      Rear oil seal housing          5/16" x 1"
>      Electric fuel pump bracket   5/16" x 3/4"
>      Accessory drive bolts            3/8" x 3 3/4"
>
> 3)   Copper flat washers under water jacket side plate bolts, under
>      the reversing gear cover plate, and under the lower three bolts
>      in the rear oil seal housing.
> -------------------------------------------
>        MOYER MARINE INC.
>   http://www.moyermarine.com
>
>
>

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