Got an engine block to build for KA-T Project - Advice?

[airman86]

Well folks I finally got a ka24de which I will be getting fully machined, bored and decked blah blah blah and fully built with forged internals. This is my first time working on a ka24de - what should I know and look out for? What are common mistakes made when assembling/etc these motors? I've built motors before so I know general deals/plastigaging/following the FSM, but I wanted to see if there is anything I need to look out for specifically on this motor.

[480sx]

Make sure you put the insert between the block and the lower front timing cover.

Dont eff up the oil squirters, they are brittle.

Put the exhaust camshaft sprocket on first, then the intake camshaft sprocket. It can be a PITA, you have to make sure the tensioner is fully depressed. Helps a lot to use a pin, there is a hole for a retaining pin for the tensioner. If you buy a OEM timing kit like you should, it'll come with it. Having a large adjustable wrench at least to move the intake camshaft to get the cam gear on is needed. Its better to use the right sized wrench.

Like any other motor, there is only one way the rods go in. Pay attention to which way the tangs for the bearings are facing on the rods, and make sure you put them back in that orientation.

Take off the oil distribution block before you hot tank it. Replace the gasket with an OEM gasket, and torque it back down when you assemble.

Use Permatex Ultra Grey as your RTV. Say your tightening the main timing cover bolts to 18 nm. After you put your RTV on and mate the cover with the block, tighten the main bolts down to say, 5 nm. Let it sit for an hour, then torque it all the way down. This gives the RTV time to set up. Do the same with the oil pan, and every single thing that uses RTV. You want to snug it, then hit it another 1/4th or so a turn down to torque specs.

Dont mix up the valve buckets, make sure they stay in their respective sleeve. Label them. Dont turn the head upside down with the buckets in and the cams out, rotf.

Dont forget the oil pick up gasket.

FOLLOW THE FSM EXPLICITLY.
Modified by 480sx at 1:05 PM 5/27/2009

[airman86]

Great info there. What markings on these engines show the orientations of the rods and pistons? I've seen several build threads that have arrows in permanent marker on the pistons all pointing one way, what was that about?

[480sx]

About exactly what i mentioned, rod orientation. To make SURE you get it right.

[airman86]

About exactly what i mentioned, rod orientation. To make SURE you get it right.

ok while disassembly, taking rods out one at a time, i marked on the rod and rod caps which cylinder they belonged to and the direction they pointed. but, for example, if i get forged rods/etc, what determines the way they point?

[480sx]

The direction of the tangs. Same deal as stock ones, the tangs have to be on the same side of the block as they were on the stock rods.

[WDRacing]

Good stuff Nate

Keep the build advice coming, I'll add this to our sticky.

WD

[airman86]

nice. alright, thanks for the advice about the rods. i have noted which way they face. I just dropped the engine off at the machine shop. pictures to come when it returns.

[airman86]

should be hearing from the machine shop tomorrow or thursday.

anything else? say if i want to paint the block something like a semi-gloss black, is there anything someone can recommend? obviously something high-heat.

[Marktheace]

id go for a brighter color so that if there are any leaks you can easily notice them.

[airman86]

hah that's actually some good advice, but i don't really like bright colors. at least on engines.

[Marktheace]

even something as subtle as a bright silver or a metallic blue

[480sx]

I like flat black. Anything shiny and you got a leak.

However as far as a specific engine coating that is flat black im not sure.. All engine block coatings are not equal.

[Jgalt240sx]

As mentioned, FSM step by step.... Oh and if using MLS head gasket I have had problems with it sealing, so I use copper spray and coat the head gasket with two coats or so... my two cents....

[airman86]

is a felpro head gasket good enough? I'm not gonna be running huge numbers (at least for 6-8 months till i turbo the thing) but when i do, i'll be running 400+hp.

As far as the update goes, my arp studs arrived, my gasket set came a few days ago, and the clevites come tuesday. I got me a nice craftsman torque wrench I can trust to assemble this thing.

The machine work got a little delayed due to the guy getting food poisoning. He said he would "try" to have it done friday, i told him not to rush. I didn't hear from him but i will be calling him tomorrow. It should be done soon.

I will start my project thread after the engine arrives. I'm ordering pistons tomorrow.