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Complete engine teardown to bare shortblock how-to with pictures

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07-23-2009, 01:25 AM

RotaryResurrectionengine builder

Trader Score: (1)Join Date: Feb 2005Location: Morristown,Tn (east of Knoxville)Posts: 994

Complete engine teardown to bare shortblock how-to with pictures

Here is a writeup to go with my engine removal how-to elsewhere. After the engine is pulled out of the car in it's complete form, you'll usually be either rebuilding the existing engine block, or using anotheroff your block. There are many ways of doing this, but this method is the most efficient and probably the fastest. Knowing exactly in what order to do things and where each bolt and plug is helps a lot.

This also assists customers of mine who wish to send in their engine block for rebuild. Although I do offer a "longblock" service whereby customers can send their complete engine (as shown below), the genexchange a bare shortblock, which is what you will end up with at the end of this writeup.

When it is engine rebuild time for you guys, remember which builder took time to photo document, transcribe, and post this procedure for free on your forum for your assistance.

First we have the engine hanging here on the hoist exactly as I pull it out of the car.

Complete engine teardown to bare shortblock how-to with pictures - RX8... http://www.rx8club.com/showthread.php?t=178945

1 от 46 30/11/2010 22:25

Now, I will obviously be using an engine stand, although it is NOT a requirement...it just makes things easier and less messy. A few things have to be removed before the engine stand head can be mounte

Remove the front oil cooler line.

Remove the 12mm bolt holding the engine ground bracket to the bottom of the intermediate iron on the driver side.

Remove the retaining clip and unplug the oil level sensor in the drivers side of the oilpan. This wire is clipped onto the aforementioned bracket, so separate this clip from the bracket.

Remove the 3 10mm bolts holding down the coil brackets to the front cover. UNplug the 4 coils and the plug wires. Remove the 12mm bolt holding the alternator wire on to the alternator, remove the clip ho


2 от 46 30/11/2010 22:25

At this point the engine can be mounted on the engine stand.


3 от 46 30/11/2010 22:25

Unbolt knock sensor from rear rotor housing. Remove spark plugs. Use a 24mm socket to remove the oil pressure sending unit.


4 от 46 30/11/2010 22:25

Remove rear heater core hose from pipe on rear iron.


5 от 46 30/11/2010 22:25

Remove air control valve...disconnect vacuum hose, remove bolt on top bracket, and 2 bolts on exhaust manifold. Disconnect wiring harness clip.


6 от 46 30/11/2010 22:25

Remove exhaust manifold and gasket.


7 от 46 30/11/2010 22:25

Remove both fuel lines from the retaining clips under the intake manifold on the drivers side. Simply pry the clips apart with a small screwdriver.


8 от 46 30/11/2010 22:25

Use a long extension and socket to remove the 2) 10mm bolts facing down from the retaining clip under the intake manifold.


9 от 46 30/11/2010 22:25

Remove upper intake manifold. Disconnect vacuum hose from the rear drivers side, 5 bolts on passenger side top, plug to vacuum solenoid on top front behind the oil filler neck, 1 coolant hose on top of theelectrical connector to the throttlebody. Lift upper intake/throttlebody combo off carefully.


10 от 46 30/11/2010 22:25

remove oil filler neck. Remove 3 solenoid plugs from the back, 2 vacuum solenoids from port actuators, harness clip, and 2 nuts at base of the neck.


11 от 46 30/11/2010 22:25

Remove extension manifold...


12 от 46 30/11/2010 22:25

Remove a/c belt tensioner from front cover.Unbolt crank angle sensor and remove clips holding harness to front cover. Lay aside on top of the engine harness.


13 от 46 30/11/2010 22:25

Unplug alternator plug.


14 от 46 30/11/2010 22:25

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__________________02 Denali: Intake, tune, z06 cam, drop, 24's, full a/v system04 RX-8: AT to MT swapped85 Corvette: fully restored


15 от 46 30/11/2010 22:25

Last edited by RotaryResurrection; 07-23-2009 at 07:04 PM.

07-23-2009, 01:39 AM


Trader Score: (1)Join Date: Feb 2005Location: Morristown, Tn(east of Knoxville)Posts: 994

Remove air hose to vacuum splitter at the base of the primary fuel injector rail.

Unplug all 6 fuel injectors (4 for automatic 4port models)...label each as you do for clarification later as they can be easy to mix up.


16 от 46 30/11/2010 22:25

Unplug and remove from bracket, the plug for the microswitch on the port actuator. Unplug coolant temp sensor. Unplug aux port actuator solenoid.

Remove water pump pulley.


17 от 46 30/11/2010 22:25

Remove alternator bracket and alternator.


18 от 46 30/11/2010 22:25

Unplug OMP connectors, unclip harness from front cover, lift and lay aside with rest of engine wiring harness.


19 от 46 30/11/2010 22:25

Unbolt harness retaining bracket from top of block (4 bolts total) and remove bracket/harness as a unit.


20 от 46 30/11/2010 22:25

Remove fuel line between primary and secondary fuel rail, at secondary fuel rail blue clip.


21 от 46 30/11/2010 22:25

Unbolt and remove lower intake manifold, being careful of auxiliary port sleeves that come out of the block with the manifold. Sometimes it takes several tugs and pushes to get these out of the block whe


22 от 46 30/11/2010 22:25


23 от 46 30/11/2010 22:25

Remove primary fuel rail/injectors.


24 от 46 30/11/2010 22:25

Remove rear oil cooler line and oil filter pedestal as a unit.


25 от 46 30/11/2010 22:25

Remove small rear coolant line from passenger side of rear iron.


26 от 46 30/11/2010 22:25

Remove clutch and flywheel. If you are sending an engine to me (or most other engine builders) you can leave the flywheel in place for me to remove for you, as it requires a special socket to remove, so it


27 от 46 30/11/2010 22:25


28 от 46 30/11/2010 22:25

07-23-2009, 01:42 AM


Trader Score: (1)Join Date: Feb 2005Location: Morristown, Tn(east of Knoxville)Posts: 994

Remove the oil injector nozzles with a 19mm wrench.


29 от 46 30/11/2010 22:25

Remove OMP lines and OMP as a unit.


30 от 46 30/11/2010 22:25

remove thermostat housing and lines as a unit.


31 от 46 30/11/2010 22:25

Top end is now stripped.


32 от 46 30/11/2010 22:25


33 от 46 30/11/2010 22:25

Flip the engine over, remove the oil pan and pickup tube. Use a stiff putty knife and hammer it between the engine and oil pan in one corner. Then hammer the putty knife from the side, all around the oilpthe flange.


34 от 46 30/11/2010 22:25

Engine is now stripped and ready to be disassembled or returned as a core.

07-23-2009, 02:32 AM

BrettusK1W1 333whp club founder

Trader Score: (1)Join Date: Apr 2006Location: Y-cat-o NZPosts: 10,164

Good work . Will keep this handy for next time i take the engine out

BTW that engine looks to have some serious oil control issues !!!__________________

Quote:

Originally Posted by Mawnee I will now be offering my Turbo kit to the public! This kit is capable of producing 900 crank HP. It is possible that I may have at one time in some way perhaps hit these numbers in my own car. may or may not, though probably not(though you could get lucky!) contain a turbo capable of these numbers.

07-23-2009, 06:23 PM


35 от 46 30/11/2010 22:25

rotarygodProud to be arrogant!

Trader Score: (0)Join Date: Apr 2003Location: HoustonPosts: 8,781

Oil o-ring failure on the rear rotor?__________________"None of us on our own is as dumb as all of us combined."

"Torque is a variable. Horsepower is the answer!"

"Meat is murder, tasty tasty murder!"

07-23-2009, 06:24 PM

Renesis SE3PPoop on a stick!

Trader Score: (21)Join Date: Aug 2006Location: SoCalPosts: 3,846

More epicness...__________________

Please refrain from being an RX-8 fanboi. RX-8 fanboiz are gay, are you gay?

Mods - Ebay fart can, Ebay Power Chip, Electric Turbonator, Vortex, Blinker Fluid, Drilled Slotted Brake Lines

07-23-2009, 06:24 PM

Jedi54Zaino Master

Trader Score: (5)Join Date: Mar 2004Location: Newport Coast, CaPosts: 17,174

excellent DIY RR.I'm hoping I never need this info but if I do....

Thanks.__________________

Jedi54's Garage

07-23-2009, 06:59 PM


Trader Score: (1)Join Date: Feb 2005Location: Morristown, Tn (eastof Knoxville)Posts: 994

Quote:

Originally Posted by rotarygod Oil o-ring failure on the rear rotor?

oil starvation to rear rotor and rear main...destroyed both adjacent irons, rotor, shaft, all bearings, rear rotor oil control rings, cutoff rings, and side seals.

Here is the teardown if you're interested in looking, but I warn you, it's ugly...

http://www.rotaryresurrection.com/builds.php/campos

09-10-2009, 08:35 PM

@!!narotordoFLAME ON!

Trader Score: (0)Join Date: Jul 2009Location: Strip ClubPosts: 955

Wow good read. Thanks for posting this.__________________

{FS} NEW ENGINE MOUNTS & ENGINE TRAYhttp://www.rx8club.com/showthread.php?t=206016BUY THEM YOU MUST!

09-10-2009, 10:01 PM

nycgpsA FC3S and SE3P guy

Trader Score: (0)

Quote:

Originally Posted by RotaryResurrection oil starvation to rear rotor and rear main...destroyed both adjacent irons, rotor, shaft, all bearings, rear rotor oil control rings, cutoff rings, and side seals.

Here is the teardown if you're interested in looking, but I warn you, it's ugly...

http://www.rotaryresurrection.com/builds.php/campos

wow ... just finished looking at those pics. 1/2 of them are trash

__________________Next time if you want to say something, please shut up. Thanks!


36 от 46 30/11/2010 22:25

Join Date: Jun 2005Location: New York CityPosts: 14,214

09-10-2009, 10:04 PM

AtillaIT'S ADVENTURE TIME!

Trader Score: (0)Join Date: May 2007Location: Caca CaliPosts: 5,073

Excellent thread....__________________

Quote:

Originally Posted by RIWWP

WET ASS

10-30-2009, 09:11 PM

diabolical1i'm the undead

Trader Score: (0)Join Date: Jul 2004Posts: 216

i can't wait to get my hands on one of these things!__________________1984 Mazda Rx-7 (in gestation once again)2004 Mazda Rx-8

Quote:

Originally Posted by ricky356

...and i would put money on it you have neither an 8 or 350....or any friends for that matter. and your mom cant stand the thought she birthed you.

10-30-2009, 09:15 PM

ZumnRx8RX8 & RX7 owner

Trader Score: (0)Join Date: Mar 2008Location: So. CaliforniaPosts: 4,433

i hate because i have no skills near this..__________________RX7club.com & RX8club.com username= ZumnRX8

8/2010 - Proud Owner of a 1988 RX7 Convertible N/A Red All Originial- .9/2005 - Proud Owner of a 2004 RX8 GT+Navi, Winning Blue Blown & Being Rebuilt

10-31-2009, 01:00 PM



Quote:

Originally Posted by Atilla's signature

Quote:

Originally Posted by diabolical1

i can't wait to get my hands on one of these things!

hmmm.....

11-30-2009, 10:18

PM


37 от 46 30/11/2010 22:25

zacknoldenRegistered User Trader Score:(0)Join Date: Apr2008Posts: 50

Quote:

Originally Posted by RotaryResurrection Here is a writeup to go with my engine removal how-to elsewhere. After the engine is pulled out of the car in it's complete form, you'll usually be either rebuilding the existing engine block, or using another enoff your block. There are many ways of doing this, but this method is the most efficient and probably the fastest. Knowing exactly in what order to do things and where each bolt and plug is helps a lot.

This also assists customers of mine who wish to send in their engine block for rebuild. Although I do offer a "longblock" service whereby customers can send their complete engine (as shown below), the generaor exchange a bare shortblock, which is what you will end up with at the end of this writeup.

When it is engine rebuild time for you guys, remember which builder took time to photo document, transcribe, and post this procedure for free on your forum for your assistance.

First we have the engine hanging here on the hoist exactly as I pull it out of the car.

Now, I will obviously be using an engine stand, although it is NOT a requirement...it just makes things easier and less messy. A few things have to be removed before the engine stand head can be mounted.

Remove the front oil cooler line.

Remove the 12mm bolt holding the engine ground bracket to the bottom of the intermediate iron on the driver side.

Remove the retaining clip and unplug the oil level sensor in the drivers side of the oilpan. This wire is clipped onto the aforementioned bracket, so separate this clip from the bracket.

Remove the 3 10mm bolts holding down the coil brackets to the front cover. UNplug the 4 coils and the plug wires. Remove the 12mm bolt holding the alternator bracket on to the alternator, remove the clip hoetc.

At this point the engine can be mounted on the engine stand.

Unbolt knock sensor from rear rotor housing. Remove spark plugs. Use a 24mm socket to remove the oil pressure sending unit.

Remove rear heater core hose from pipe on rear iron.

Remove air control valve...disconnect vacuum hose, remove bolt on top bracket, and 2 bolts on exhaust manifold. Disconnect wiring harness clip.

Remove exhaust manifold and gasket.

Remove both fuel lines from the retaining clips under the intake manifold on the drivers side. Simply pry the clips apart with a small screwdriver.

Use a long extension and socket to remove the 2) 10mm bolts facing down from the retaining clip under the intake manifold.

Remove upper intake manifold. Disconnect vacuum hose from the rear drivers side, 5 bolts on passenger side top, plug to vacuum solenoid on top front behind the oil filler neck, 1 coolant hose on top of the threlectrical connector to the throttlebody. Lift upper intake/throttlebody combo off carefully.


38 от 46 30/11/2010 22:25

remove oil filler neck. Remove 3 solenoid plugs from the back, 2 vacuum solenoids from port actuators, harness clip, and 2 nuts at base of the neck.


39 от 46 30/11/2010 22:25

Remove extension manifold...


40 от 46 30/11/2010 22:25

Remove a/c belt tensioner from front cover.Unbolt crank angle sensor and remove clips holding harness to front cover. Lay aside on top of the engine harness.


41 от 46 30/11/2010 22:25

Unplug alternator plug.


42 от 46 30/11/2010 22:25

I'm gonna need this detailed DIY. I just got my work messed up following just indtructions without any illustrations._______________________________________________Hit the Road with SEMO

Last edited by zacknolden; 06-02-2010 at 08:47 PM.

12-01-2009, 01:36 AM



Quote:

Originally Posted by zacknolden

I'm gonna need this detailed DIY. I just got my work messed up following just indtructions without any illustrations.

Wat?


43 от 46 30/11/2010 22:25

12-01-2009, 02:13 AM

@!!narotordoFLAME ON!

Trader Score: (0)Join Date: Jul 2009Location: Strip ClubPosts: 955

Now thats a real do it your selfer

__________________

{FS} NEW ENGINE MOUNTS & ENGINE TRAYhttp://www.rx8club.com/showthread.php?t=206016BUY THEM YOU MUST!

12-04-2009, 11:21 AM



Wat?

12-21-2009, 11:18 PM

SchartzDuluth/Superior

Trader Score: (3)Join Date: Apr 2009Location: Soup TownPosts: 24

How many miles where on the engine when you started taking it apart?

02-28-2010, 01:22 AM

Nemesis8Bigus Rotus

Trader Score: (3)Join Date: Jun 2004Location: Banks of The MuddyWishkahPosts: 8,184

I would so purchase a bolt kit for all the bolts used in this tear-down, if it was available. It would be awesome to have a set in a bag labeled for what they are.

I have a project I could use them on.

__________________vGarage

03-14-2010, 04:31 PM

TeamRX8The Unknown Autocrosser

Trader Score: (5)Join Date: Apr 2005Location: In your mind &under your oversensitive skinPosts: 9,842

the parts PDFs which will show what and where__________________

Doesn't play well with others self-imposed ban to non-text mode

03-14-2010, 07:29 PM

dannobreBack is Back...Front next

Now you're getting crazy You going to ceramic coat the bolt heads?

__________________


44 от 46 30/11/2010 22:25

Trader Score: (0)Join Date: Feb 2004Location: SmallvillePosts: 6,838

03-14-2010, 07:37 PM

Nemesis8Bigus Rotus

Trader Score: (3)Join Date: Jun 2004Location: Banks of The MuddyWishkahPosts: 8,184

I was thinking something along those lines...

__________________vGarage

06-13-2010, 05:44 AM

king angelsRegistered User Trader Score: (0)Join Date: Jun 2010Posts: 3

Best advice if you are on a budget low miles van at junk yard but if u want take too machine shop complete head work about 250-325 but first just have the junk yards heads checked if bad take backthe time there okay.__________________Toronto Limousine Services | Splash Surf Mag Blog | Silver and Teal Blog

06-13-2010, 12:26 PM

shadycrew31Registered User Trader Score: (2)Join Date: Apr 2008Posts: 1,417

^ spam?

06-13-2010, 12:26 PM

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RX8 - Complete-engine-teardown