1. Before starting any work on the engine, it's crucial to consult the specifications and guidelines provided in the engine's service manual. This manual contains valuable information on clearances, tolerances, and torque values.
2. Ensure that all necessary parts and tools are available before beginning the project. This includes the 396 big-block engine, cylinder heads, intake manifold, carburetor, pistons, camshaft, crankshaft, connecting rods, and all required gaskets and seals.
Disassembly and Inspection
1. Begin by carefully disassembling the engine. This involves removing the cylinder heads, intake manifold, oil pan, and other components necessary to access the block and crankshaft.
2. Thoroughly clean all disassembled parts, removing dirt, carbon deposits, and old sealant. Pay close attention to the condition of the surfaces where mating parts will fit.
3. Carefully inspect all disassembled components for wear, damage, or defects. Replace any worn or damaged parts as needed.
Installing the Pistons and Connecting Rods
1. Choose high-quality forged pistons and connecting rods that match the specifications of the engine. Forged components are stronger and more reliable than cast components, particularly for performance applications.
2. Resize connecting rods to fit the new pistons, if necessary. This ensures proper clearance and longevity of the engine.
3. Install the pistons into the cylinders and connect the connecting rods to the crankshaft. Properly torque all relevant fasteners according to the service manual specifications.
Installing the Camshaft
1. If a new camshaft is being used, consult the camshaft manufacturer's guidelines for proper installation.
2. Install the camshaft into the block and align the timing gear. Make sure the timing marks are aligned correctly.
3. Install the camshaft bearings, checking for proper clearance as specified in the service manual.
Installing the Cylinder Heads
1. Prepare the cylinder heads by replacing any worn or damaged valves, valve springs, and seals.
2. Properly align the cylinder heads with the block, checking that all dowel pins are seated correctly.
3. Apply a thin layer of high-temperature gasket sealant to the head gaskets and install them between the cylinder heads and the block.
4. Install the cylinder heads and torque them in the proper sequence and torque specifications as outlined in the service manual.
Intake Manifold and Carburetor Installation
1. Mount the intake manifold onto the cylinder heads, ensuring a proper seal and correct bolt thread engagement.
2. Install the carburetor onto the intake manifold. Properly adjust the fuel mixture and idle speed as specified in the carburetor's manufacturer guidelines.
Final Assembly and Testing
1. Continue to assemble the engine, installing all remaining components, including the oil pump, water pump, timing chain or belt, distributor, spark plugs, and any necessary sensors or accessories.
2. Once the engine is fully assembled, connect all necessary electrical and fuel lines. Fill the engine with oil and coolant, and connect the battery.
3. Perform a thorough leak test to ensure there are no leaks in the oil, fuel, or coolant systems.
4. After confirming the engine is properly assembled, start the engine and let it run for a short period to assess its functionality and listen for any unusual noises or vibrations.
5. Perform any final adjustments to the carburetor or ignition system, if necessary.
Note: Building a 396 Chevy big block engine requires considerable technical knowledge, experience, and proper tools. If you are not comfortable performing such a complex task, it's advisable to seek the assistance of a professional automotive machinist or engine builder.
