3800 Series 1 Complete Tear Down

As you will see by the pictures the engine is already out of a car so no wiring harness, fuel rails, or plug wires to do but none of those are hard to disconnect, you just have to search around for every sensor.

Im sure you'll also be able to tell that this engine is far from being a virgin due to previous classes tearing it down and having no idea what their doing (I saw a kid use a dead blow to remove the main rod caps...)

Pretty much every bolt on this engine is a 10mm, 13mm or 15mm other than your cam and crank bolt which I cannot remember off the top of my head. But I think they might be cam - 24mm and crank 18mm.





Step 1 - Remove the supercharger

Step 2 - Remove the valve covers



Step 3 - Remove the LIM (this has a torque sequence so reverse and use it as a de-torque sequence, also when detorquing do a 1/3rd turn on each bolt to even distribute the load as to not cause warpage.)



Step 4 - Remove the rockers and pushrods (keep them in order, we used a wood block drilled out so that each pushrod will go back into the cylinder is came out of, make sure the rockers all in order aswell.)

Step 5 - Remove the heads





OMG WERE MISSING A PISTON!


Step 6 - Remove the front cover



Step 7 - Remove the timing chain dampener

Step 8 - Remove the cam bolt (if your having trouble you can use your old crank bolt and put it in the crank to hold the crank while you remove the cam bolt.)

Step 9 - Removing the timing chain and gears

Step 10 - Remove the oil pan (dont bash your head on the oil pan you've come this far!!)






Step 11 - Remove Pistons

You going to make sure the piston your removing is at Bottom dead center then unbolt the connecting rod, remove the cap. To properly remove the piston you'll use a special J-tool to screw into the connecting rod and the gently push it down and out the cylinder.





Step 12 - Remove the main bearing caps

These are pressed in so to correctly remove them you'll need to use the J-tool. It has two shims that go into the bolt holes and you tightening them to 100 in/lbs then you put the end of the slide hammer in the middle hole on the puller and pop em on out.




Step 13 - Get all of your measurements to make sure everything is intact and start putting the engine back together



I'll try and get a few more pictures tomorrow if I go to school and get some measurements for all of you

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GPDIY - For All Your DIY Needs
VS CAM|3.4|HEADERS|FWI|42.5#|HPT|6000k LOWS|8000k FOGS|

Nice...wish we had a supercharged 3.8 to tear apart when i took my auto tech classes!!, we had old v-8's which i liked and a new 3.5 out of a chevy malibu which by the time 200 students got done with it you would have thought it had 300k+ miles and wasnt worth the aluminum it was made out of lol

Haha we had a few nice engines. Got to play with a 351 modified. It was some hillbilly botch job lol

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GPDIY - For All Your DIY Needs
VS CAM|3.4|HEADERS|FWI|42.5#|HPT|6000k LOWS|8000k FOGS|

I wish I was doing what you do at school. I'd be way more interested in it than art history.

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'05 WRX STi - COBB Stage 2|Invidia DP|3" Borla XR-1|Coilovers|Camber Plates|Swaybars|Endlinks|Bushings|Braces|Anti Lift Kit|DBA4000s|SS lines|
Sold: 06 Cobalt SS/SC, 99 GTP 245WHP/326 Ft-lbs, 06 R6

nice write up... now tear down your engine lol

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180 T stat, HV3, Wizaired Intake, GMPP Exhaust, Speed Daddy Headers, 1.9 Yella Terra Rockers, Eibach Springs on KYB AGX Struts, Custom LED interior light switches, BBEngineering.com 6 Pod Cluster, Poly Mounts and Bushings, Mild Tune, Gen 3 Coming Soon with L26 block, HPTuner

kyle you shoulda started with me, it could have been you, me, and matt living up in cleveland!

I really want an L26 block to have in my garage right now

_________________

GPDIY - For All Your DIY Needs
VS CAM|3.4|HEADERS|FWI|42.5#|HPT|6000k LOWS|8000k FOGS|

We should have. It would have been awesome. BTW, aren't those valve covers flip flopped haha.

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Dubs:00 VW GTI VR6, Low and Slow 91 VW GTI 8v, Shave the Bay!! 91 VW Cabriolet 8v, bitch Basket
GP's:04 GP GT, Past now G-Ma's Girlfriend's 97 GP GT, "Project Pink Power"

For real. Instead I'm going to "kent read, kent write, kent state".

-- Fri Dec 24, 2010 3:32 am --



They are flip floped, nice catch.

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'05 WRX STi - COBB Stage 2|Invidia DP|3" Borla XR-1|Coilovers|Camber Plates|Swaybars|Endlinks|Bushings|Braces|Anti Lift Kit|DBA4000s|SS lines|
Sold: 06 Cobalt SS/SC, 99 GTP 245WHP/326 Ft-lbs, 06 R6

I get a headache just looking at this... I've gotten to the point where I can dissaeble my engine to the rockers and lifter in under an hour... Counting me being organized about it.

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Why have more money than brains? Cuz RACE CAR :

Lol the valve covers are flipped, that was before I fixed it :p

_________________

GPDIY - For All Your DIY Needs
VS CAM|3.4|HEADERS|FWI|42.5#|HPT|6000k LOWS|8000k FOGS|

You're going to have to follow Matt and I to NC though Derek, Cleveland is closer to the cold, not further away.

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'05 WRX STi - COBB Stage 2|Invidia DP|3" Borla XR-1|Coilovers|Camber Plates|Swaybars|Endlinks|Bushings|Braces|Anti Lift Kit|DBA4000s|SS lines|
Sold: 06 Cobalt SS/SC, 99 GTP 245WHP/326 Ft-lbs, 06 R6

When we going to NC?

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GPDIY - For All Your DIY Needs
VS CAM|3.4|HEADERS|FWI|42.5#|HPT|6000k LOWS|8000k FOGS|

We're moving there. Matt's girlfriend and my girlfriend are both teachers and they'll have better luck getting jobs down south. Matt and I will never have to buy snow tires again. We all win. You're welcome to join.

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'05 WRX STi - COBB Stage 2|Invidia DP|3" Borla XR-1|Coilovers|Camber Plates|Swaybars|Endlinks|Bushings|Braces|Anti Lift Kit|DBA4000s|SS lines|
Sold: 06 Cobalt SS/SC, 99 GTP 245WHP/326 Ft-lbs, 06 R6

^^^ aww no florida?

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Sounds like a good idea to me. If I can get a job at Underground Racing well be set haha!

_________________

GPDIY - For All Your DIY Needs
VS CAM|3.4|HEADERS|FWI|42.5#|HPT|6000k LOWS|8000k FOGS|

UR is kick ass!!!!!!! Party in NC!!!!!!

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Dubs:00 VW GTI VR6, Low and Slow 91 VW GTI 8v, Shave the Bay!! 91 VW Cabriolet 8v, bitch Basket
GP's:04 GP GT, Past now G-Ma's Girlfriend's 97 GP GT, "Project Pink Power"

Lets do it!

_________________

GPDIY - For All Your DIY Needs
VS CAM|3.4|HEADERS|FWI|42.5#|HPT|6000k LOWS|8000k FOGS|