Engine rebuild specification, Engine no. TS12629E
Piston & Liner diameter is 87mm
Rear lip oil seal conversion
Mains @ .040”
Bigs @ .050”
Thrusts @ STD/.005”
Bearings manufactured by King
Head is converted to lead free, new guides, new valves, new springs, refaced, valve seats cut, cleaned, crack tested etc.
Also, new chain, tensioner, new cam followers, new camshaft bearings, reprofiled camshaft, new rocker shaft, new rockers.
I have attached a general build sheet to this email so your customer will have an idea of the processes that his engine has gone through.
Kind regards,
Toby. Classic & Modern Engine Services Ltd
18 – 20 Great Hollands Square,
Tel: (01344) 488853
Fax: (01344) 300144
Engine rebuild procedure
Below is a general guide to our engine rebuild procedures for a standard “lead-free” overhaul.
Head:
Stripped
Roto-blasted to clean bare metal
Threads checked and repaired as necessary
Crack tested
New valve guides fitted
Valve guides reamed
New exhaust seats fitted (lead-free conversion)
Cylinder head refaced
Inlet valve seats re-cut
Exhaust valve seats cut to appropriate angle
New valves installed
New valve springs fitted
Valve to seat pressure checked
Valves vacuum tested to ensure correct sealing
Block:
Stripped (all oil galleries removed, all core plugs removed)
Acid dipped
Ultrasonic cleaned
Wire brushed and checked for damage/cracks
Oil galleries brush cleaned
Threads checked and repaired as necessary
Re-bored to new pistons
Refaced
Camshaft bearings fitted (where appropriate)
Piston ring gaps checked
New core plugs fitted
New oil gallery plugs fitted
Crank:
Cleaned
Ultrasonic cleaned
Gallery sludge plugs removed
Threads checked /repaired as necessary
Reground as necessary
Galleries cleaned
New sludge plugs fitted
Con-Rods:
Acid dipped
Ultrasonic cleaned
Small ends removed (where applicable)
Big end housings checked for size and “round”
New small end bushes fitted (where applicable)
Small ends bored to match gudgeon pin
Rocker shaft:
Stripped
Rockers and pedestals ultrasonic cleaned
Rockers re-profiled
New rocker bushes fitted (where applicable)
Rocker bushes honed to new rocker shaft
Parts used:
New guides
New valves
New springs
New exhaust seats
New rocker bushes (where applicable)
New pistons
New piston rings
New small end bushes (where applicable)
Re-profiled camshaft
New camshaft followers
New timing chain
New timing chain tensioner
New oil pump (where original unserviceable with new internals)
New oil pressure relief valve
New oil pressure relief spring
New spigot bush (where applicable)
Full head gasket set
Full conversion set
New Front and rear crankshaft oil seals (where applicable)
New big end bearings
New main bearings
New thrust washers
New engine lock tab set
New core plugs
New oil gallery plugs
New camshaft sprocket (where original unserviceable)
New crankshaft sprocket (where original unserviceable)
New big end bolts (where applicable)
New cylinder head nuts (where applicable)
Assembly:
Engine assembled using new gaskets, bearings, pistons and rings, camshaft timing set and tappet clearances set. Oil filled and electronically tested to 700rpm to ensure correct oil pressure, correct oil distribution and correct compression across all cylinders.