- Remove engine
- Disassemble engine
- Clean all useable engine parts
- Bead-blast all useable engine parts
- Resurface case halves
- Pre-assemble case halves and check line bore (line bore if necessary)
- Remove all old case / head studs
- Drill, tap, and install Time-Sert thread inserts for case stud strength
(If needed additional cost of $250)
- Install new 993 style case studs
- X-ray crank for cracks, check for straightness, repair if necessary, and
micro-polish
- X-ray rods for cracks, check for straightness, install new small end
bushings
- Install new rod bolts in all rods
- Recondition all pistons and cylinders (if out of tolerance new piston and
cylinder sets will be needed at an additional cost, but no additional cost
on labor)
- Install all new factory rings on all pistons
- Install pistons in cylinders
- Install new factory main bearings in case halves
- Install new factory intermediate shaft bearings in case halves
- Install rods onto crank using new factory rod bearings and new rod nuts
- Install new number 8 nose bearing on crank
- Install crank into right side case halve
- Install new intermediate shaft cam drive sprockets
- Disassemble oil pump, clean, inspect, and reassemble (note: if oil pump
has worn parts, rebuild parts are unavailable and a good used, or new oil
pump will be needed at an additional cost)
- Install new cam chains to intermediate shaft
- Install intermediate shaft and oil pump as an assembly into right side
case halve
- Apply factory case sealant to case halves
- Install left side case halve to right side case halve using all new yellow
chromium hardware Install piston/cylinder sets using new piston pins and
retainers
- Disassemble cylinder heads
- Bead blast all heads
- Install all new factory valve guides
- Perform minor port work to all heads
- Perform 5 angle valve job to all heads
- Regrind all intake and exhaust valves (note: any valves out of factory
specifications will be replaced with brand new valves at no extra charge)
- Install all new valve stem seals
- Install valves into cylinder heads using brand new factory valve springs
- Install all cylinder heads to cylinders using new head nuts and washers
- Install Jet Hot coated cylinder sheet metal baffling between cylinders
- Install new Jet Hot coated oil return tubes
- Install cam towers using all new yellow chromium hardware
- Install cam chain housings
- Inspect and micro-polish cams ( if cam repair or replacement is needed it
will be at an additional cost)
- Install cams
- Install new cam sprockets
- Adjust cam sprocket parallelism
- If needed - install new oil feed type cam chain tensioner kit (extra cost
of $650)
- X-ray all rocker arms for cracks
- Install all new bushings in rocker arms
- Install rocker arms using all new shafts and shaft hardware
- Adjust valve lash to 0.004"
- Adjust cam timing to factory specifications
- Install new factory spark plugs
- Install new powder coated (your choice of color) cam chain housing covers
using new yellow chromium hardware
- Powder coat upper and lower valve covers (your choice of color)
- Resurface valve covers and install using new yellow chromium hardware
- Paint fiberglass engine shroud choice of color using fuel /oil proof
Sikkens paint and install
- Install engine harness
- Powder coat (choice of color) alternator / cooling fan housing
- Install new alternator in fan housing (if needed at additional cost of
part only)
- Powder coat cooling fan (choice of color) and install on alternator
- Install fan housing / alternator assemble on to engine
- Install new alternator belt and new outer pulley half
- If carbureted – rebuild carburetors, and install
- If mechanical fuel injection - sub out pump for rebuild (extra cost of
$850 if needed)
- If mechanical fuel injection - mount pump, install new drive belt, and
adjust pump timing
- If mechanical fuel injection – mount throttle bodies to engine
- If CIS injection - reseal intake air box, and install new back-fire trap
door (no extra cost)
- If CIS injection- install all new fuel injectors (additional cost of part
only if needed)
- If CIS injection - install new warm-up fuel pressure regulator (additional
cost of part only if needed)
- If CIS injection - install new aux air regulator (additional cost if
needed)
- If CIS injection - install all new intake boots to intake runners, and
install intake assembly to engine
- Replace all vacuum hose
- Install new bushings in throttle linkage pivot
- Replace all crank case breather hoses
- Optional $350. If in good condition- Jet Hot coat complete exhaust system (If new exhaust
is needed, it will be at an additional cost).
- Install exhaust system to engine
- Reinstall ignition distributor
- Install new ignition rotor and distributor cap
- Install all new factory plug wires
- Powder coat (choice of color) all engine sheet metal and install using all
new yellow chromium hardware
- New factory top end and bottom end gasket sets are included in engine
rebuild
- Resurface flywheel and install (if new flywheel is needed it will be at an
additional cost)
- Inspect clutch and install (if new clutch is needed it will be at an
additional cost)
- Reinstall transmission to engine
- Reinstall engine into car chassis
- Install new engine oil filter
- Install 11 quarts of lightweight break-in engine oil
- Start and tune engine
- Road test car for 100 miles
- Put car back on lift to recheck for any oil leaks
- Repair any oil leaks if needed
- Drain break-in oil
- Change oil filter
- Add 10 quarts of new 15w50 Mobil 1 synthetic motor oil
Car is now ready to pick up or deliver!
Note: After 1,000 to 2,000 miles - new engine will
need to have the valves readjusted, the oil filter and motor oil changed, and
retuned. We will do this free of charge for all of our engine rebuild
customers!