Engine assembly specs, tolerances, tips, diagrams and links document

[jibberjive]

So I also made an excel spread sheet with all of the consolidated tolerances, specs, and tips that I've accrued throughout my research and over the years. I hope to take a little of the mystery out of the DIY assembly of the rotating assembly/ heads, for anyone that might want to attempt it on their own. This should help with some of the common downfalls of the 2.7l assembly (heads mis-timed, rods installed backwards, etc). If you print it in landscape format, it's 3 pages where you can write the measurements of your engine in. Hope this maybe helps someone!

LINK PUT ON HOLD WHILE I UPDATE

Screenshots below, but use the file above to get all of the info

[jibberjive]

And if there's any mistakes, feel free to bring them to my attention!

[Hyphy]

Cool stuff man..def. Will take a look at it in detail when I'm not at work.

[A62TURBO]

Perfect timing for my engine build

[shorterthanrich]

This is awesome. You are a gentleman and a scholar, and an asset to this community!

[S4 00 2.7]

Good info to share.

Thanks.

[bigern45]

what are you doing?? stop messing around and get the S finished!!!

[Rated S]

Mind if I put this on my repair page?
I'll credit you, of course.

Really good info.

[Ribbie]

This is awesome. You are a gentleman and a scholar, and an asset to this community!

I second the above!! Nice

[Capt. Obvious]

Informative stuff like this is why I put up with all the retards on forums. LOL

THANK YOU!

[MDJ]

Awesome. Thanks for posting!

[DiscoPotato]

That handwritten timing picture saved me in the past..

Given that I know that this will help someone out on here.

Thanks for sharing!!

[goohead]

honestly when i was doing timing i tried to use that pic for the chain and mine was off using it.

also for the more visual diy a shameless plug to my walkthough http://www.cardomain.com/ride/264337...udi-s4/page-14


i would recommend the wiseco app guide here to determine ring gap http://www.wiseco.com/PDFs/Manuals/RingEndGap.pdf

you measure ring gap to the bore not the piston and should be measured to at least 1/10 thous, you should never round off until the end of your measurements, as the end result can varry, i do all my measurements on my ti89, i downloaded a free app to do " to mm conversion

example: bore= 81.5 mm = 3.20866142"

top = .005" x 3.20866142" (bore of that cylinder, not mike value of piston** do not round off***) = 0.0160433071" round to .016" < rounded value

call me anal but i'm a perfectionist i cant help it :)

[B6T]

Awesome tool, but I would stick with either mm or inch, not both.

[jibberjive]

what are you doing?? stop messing around and get the S finished!!!

Lol. You're welcome? (ps, I'm writing this from my shop, so work is getting done son)

Mind if I put this on my repair page?
I'll credit you, of course.

Really good info.

Go for it, but wait like a week because I might make a couple of updates to it.

Alot of my info came from other places (I didn't make the drawing or any of the diagrams), and I just credited it to the internet forums.

That handwritten timing picture saved me in the past..

Given that I know that this will help someone out on here.

Thanks for sharing!!

honestly when i was doing timing i tried to use that pic for the chain and mine was off using it.

I too was worried about the handwritten picture, because it goes against the Bentley. When I saw all the people that were using it, and who those people were (reputable), I decided to use it. Then, just before doing the install I realized that I had a set of 2.7 heads 5 feet away for reference that had never been disassembled. I personally verified that the picture is correct.

also for the more visual diy a shameless plug to my walkthough http://www.cardomain.com/ride/264337...udi-s4/page-14

Awesome! I thought I had seen almost all of the S4 DIY stuff (you should see my bookmarks folders), but I don't think I've ever seen yours. I'll add it to the links.

i would recommend the wiseco app guide here to determine ring gap http://www.wiseco.com/PDFs/Manuals/RingEndGap.pdf

I'll add that to the links as well. I hear all different 'rules of thumb' for the ring gap spec, but the one thing that is usually consistent is that in that equation, the top ring factor that you multiply is usually .005" smaller than the bottom. I went with .055" for the top and .060" for the bottom after doing research, but I'll probably change the recommendation on the sheet to reflect Wiseco's recommendation, so that the liability is on

you measure ring gap to the bore not the piston and should be measured to at least 1/10 thous, you should never round off until the end of your measurements, as the end result can varry, i do all my measurements on my ti89, i downloaded a free app to do " to mm conversion

example: bore= 81.5 mm = 3.20866142"

top = .005" x 3.20866142" (bore of that cylinder, not mike value of piston** do not round off***) = 0.0160433071" round to .016" < rounded value

I did measure using the bore (81mm), not the piston (80.95mm or whatever), and the equation says "bore size", but I'll change the wording in the parenthesis so that no one can confuse that. And as for rounding off, I wasn't too worried for a couple of reasons, the main reason being that we're using relatively loose, general "rule of thumb" formulas in the first place (for example, I choose the factors to be .0055" and .0060", when you and some other people might use .0050" and .0055"). Also, the stock 81mm bore works out to be 3.18897", which is well inside what I'm personally comfortable rounding up to 3.19" for me. Come to think of it though, I think I used my TI calc as well, and I don't think I rounded anything til the last spec (for the final numbers), I think I just wrote 3.19" in the general formula example

call me anal but i'm a perfectionist i cant help it :)

I'm glad for it. It's because of people like you that things can get refined and improve. I'll add those links and change a couple of words.

Awesome tool, but I would stick with either mm or inch, not both.

If you want to take the time to convert those and send me the updated file, I'll put that in the original post. If not though, if someone is disassembling their engine, I'd hope they're capable of being attentive to the units

[jibberjive]

Awesome! I thought I had seen almost all of the S4 DIY stuff (you should see my bookmarks folders), but I don't think I've ever seen yours. I'll add it to the links.

Actually I take that back, I did have your cardomain page bookmarked like 3 times, but for the engine pull stuff. I swear the engine internals stuff wasn't on there a while ago?

[goohead]

Ya u know how projects goes lol

[Rated S]

Go for it, but wait like a week because I might make a couple of updates to it.

Cool if you want to email me the 'final' I'll post it up when it's ready, in case I miss anything on the forum.
Thank's again for another helpful contribution to us.

[julex]

I will use this when starting my own assembly. Thanks man!

[DiscoPotato]

I too was worried about the handwritten picture, because it goes against the Bentley. When I saw all the people that were using it, and who those people were (reputable), I decided to use it. Then, just before doing the install I realized that I had a set of 2.7 heads 5 feet away for reference that had never been disassembled. I personally verified that the picture is correct.

Believe me, Bentley is wrong. Ive been there done that. But to make things clear: Bentley is wrong for the DRIVER side cylinder head. Passenger - follow Bentley/illustration (Illustration is more clear though), Driver - follow illustration. It will make things much easier.

[jibberjive]

Believe me, Bentley is wrong. Ive been there done that. But to make things clear: Bentley is wrong for the DRIVER side cylinder head. Passenger - follow Bentley/illustration (Illustration is more clear though), Driver - follow illustration. It will make things much easier.

As you said, the illustration is correct for the driver's side as well, so if you choose to rely on only one, make it the illustration

[diabolical1]

very useful information. thanks for posting it.