Collector Edition LT4 Build Up

[PLRX]

Some wording may refer to "yesterday" and that is wrong refer to the date on the pictures. I'm copying and pasting from the thread I posted on other forum.

August 2008, after about 4 months of looking at it, planning and wondering if I wanted to do this project I went ahead and bought a 1996 LT4 Collector Edition Vette. I paid $3,500 and it was trashed. The engine was clean in the inside and that was the #1 reason I bought it.

























There are many steps I took that I wish I didnt, I'll go to the punch-line and the end of the LT4 rebuild.

[PLRX]

This was my first time doing the whole thing. Took me couple of pistons to get the hang of it . Did the crank
and 4 pistons (Scat Crank and Rods with SRP pistons)

What you all think?:woowoo:

[PLRX]

Scat rods, SRP pistons




GM Performance 12499225 lifters








Torque down to manufacturer specs: 45 lbs ft


within specs



LLoyd Elliot's LE2 from Ultradyne cams



My old friend "The Duck" water pump gear, install with special tool and torque to 106 lbs ft in


torque to 18 ft-lbs



got some play dough




torque oil pump to 66 lbs ft and wind tray bolts to 30 lbs ft, screen is 3/8" from the oil pan, took it to the muffler shop and got it welded


apply oil to the main seal, install gasket and torque to 11 ft-lbs



applied silicone/RTV on all oil pan's corners


106 lbs in on center bolts and 15 lbs ft on corner bolts and studs


torque knock sensors to 15 lbs ft


install gasket and oil ring and torque oil filter adapter to 18 lbs ft

[PLRX]

Thread sealant



Torque to 65 ft lbs (22-45-65)




After a great C4 Yosemite Run and a harsh Monday at work I needed to relax and got busy.



Thread sealant



Torque Rocker Studs to 50 lbs ft



Torque lifter tray to 18 lbs ft, hopefully I got the roller-rockers right



Torque oil and fuel pressure sensors to 106 lbs in


The oil pressure gauge torques to 106 lbs in but I grabbed the wrong torque wrench and OOOUCH

[PLRX]

Torque oil pressure gauge sensor to 106 lbs in


Now, ENSURE you install an oil filter before you prime the engine...


...If you don't something like this could happen to you. This is a photochop not like it happened to me


LT4 is now primed and ready for intake manifold

[PLRX]

More pictures, almost there

Torque oil pump driveshaft bolt to 18 lb ft.


To install intake, clean all surfaces with brake cleaner or fast dry agent



I used 600 grit sand paper to help RTV adhere to the block and intake.


RTV








Apply thread sealant to all intake bolts.


First pass torque all bolts to 71 lb in. Use sequence illustrated in the FSM.
Second pass torque to 35 lb ft. I found all bolts adjusting until the fourth pass to 35 lb ft.




Install Opti and torque to 106 lb in.


This is the bottom right water pump bolt. It is exposed to coolant.


Apply thread sealant


Torque water pump bolts to 33 lb ft and the thermostat housing to water pump to 89 lb in.


Intake ported by Elliot Portworks


Torque the crankshaft balancer hub bolt to hub to 74 lb ft.


Torque header bolts to 30 lb ft.


Torque throttle body bolts to 18 lb ft.


New TB plate .


Torque EGR plate to 18 lb ft and engine coolant bleed pipe bolts to 30 lb ft.


Torque crankshaft balancer bolts to 63 lb ft.

[PLRX]

Installed the rack & pinion. Torque the main bolt to 30 lb ft and the clamp bolts to 18 lb ft. Torque the steering column bolt to 30 lb ft.


Torque PS cooling bolts to 86 lb in.


Get Ready-


Get Set-


Go



LT4 is back in


Don't let this pictures fool you. It not that easy, the engine doesn't just drop/fit in.

If this engine do not work or anything goes bad after all this time, work, cuts, chunks taken out of my hands and money I may go insane.

[PLRX]

So I ordered the 7777 gasket, removed the TB, AIR line and the intake. Look the RTV or bolts thread sealant
were 7 days old and they were not totally dried.


Now the path is clear



Light coat of oil to ease up installation


Torque fuel rail to 89 lb in. These are FIC Bosch III injectors, no clips required.


Connect PS line and install belt pulley. Torque bolt to 24 lb ft.


ASR components up!


New LT4 TB plate


A/C and cooling are on place and to be connected tomorrow.

[PLRX]

Clean the flywheel's surface with brake cleaner


Torque flywheel bolts to 74 ft lb


Torque pressure plate to flywheel to 30 ft lb. Use FSM tighten order.


Torque the bellhousing to engine block to 37 ft lb


Tranny do not just "slide in"


Put tranny on the floor and slide it in sideways and back on the jack.


SON of A BITCX. This sucker kicked my ***. Torque tranny bolts to 37 ft. lb. Use FSM tighten order.


ZF Doc Beam Plates


Discard washers, torque tranny bolts to 37 lb ft


Discard washers, torque axle bolts to 59 lb ft




The last time I install the ZF it went into the clutch/pressure plate in less than a minute today, this sucker kicked my ass twice. I'm very tired. I need to by a lift

[PLRX]

Magnaflows Catalyt Converters
The passenger side came with only one O2 stud and the exit pipe was too small. Took it to the local muffler shop and problem solved





Torque clutch master to 18 lb ft. Don't forget to bleed, instructions are to be found in the FSM, a total engineering failure.


Install tranny cover plate, install starter and torque to 35 lb ft


Torque O2 sensors to 30 lb ft


Veterans Day so I took it easy. Day off , It is my day so worked on the Vette until 2:30 PM only

Magnaflow Performance Exhaust back on the Vette. This is the most unfriendly "bolt-on" system I have seen for any car.



Looks like this system was designed for an automatic. The O2 sensor plug was on the clutch master cylinder way. It was plugged and a new O2 sensor plug was installed.


The new catalyst is not 100% "fit-in". Home made exhaust pipe bender.


These bolts are one of the biggest PITA to remove and to install if you use the OEM catalyst. There was plenty of space to work there.


ZF Doc beam plate touches the muffler hang bracket. Try using a pry bar but it did not move. I'll wait, gamble and hopefully it does not create lots of resonance.


I'm done for the day. If you served and went into combat, I Salute You

[PLRX]

IT'S ALIVE

Yesterday received the ECM in the mail and this morning I didn't even got some. I went into the garage and got busy.

Got the TWS and filled up the ZF




Finished aligning the exhaust and torque the Magnaflow clamps to 50 lb ft. Now, don't come and torque your clamps to 50 lb ft,
they'll snap. Magnaflow's Performance Exhaust Clamps come with this package and instructions.


Major set-back with the camber brace. Few of us know what a PITA it is to install well... I got it done AND-I forgot to install
the serpentine belt cuss:cuss. It is on the floor, I'll get it done before alignmnet.


PCM for Less.


LT4 ready


Got some Chevron 91 + octane booster


That son of a bitch started right away Got it break in dle for 20 minutes 1,900~2,200~2,000 RPMS


Accelerator assistant




After 20 minutes, I stopped the engine. Checked the coolant, change the oil filter and all it's good.

Got to say this: The idle is smoother than before and it burns cleaner/smells less. The gddmt DMF is new and the sucker is
already making it's decease noises. It freaking scared me first, I thought it was coming from the engine.

Tomorrow I'm planning on finishing the suspension/front sway bar and will raise the rear maybe 1/4"~1/2". I'll do my best to take it for a spin.


Got the sway bar in. Torque to 40 lb ft at ride height


Something cane up to my mind. I forgot to tighten the engine mounts. Torque to 40 lb ft


Torque wheels to 100 lb ft--On the floor.

[PLRX]

A recap of the whole project


Beware, this torque specifications work for late C4 Vettes. Haynes manual says for 1988-1996.

Torque upper control arm to crossmember bolt to 37 lb ft
Upper shock bolt to 19 lb ft


Torque new ball joint bolts to 13 lb ft


This is a C5 brake kit upgrade.
Torque the kit bracket to the knuckle to 150~180 lb ft
Torque the C5 caliper bracket to C5 kit bracket to 125 lb ft
Torque caliper to caliper bracket to 25 lb ft


Torque shock lower bolts to 22 lb ft
Sway bar to upper link nut to 35 at ride height
Sway bar to lower link nut/to lower control arm to 22~35


Sway bar to frame to 40 lb ft at ride height


Lower control arm to frame to 82 lb ft


Monospring retainer bolt to 46 lb ft at ride height


Hub to bearing to knuuckle bolt and nut to 46 lb ft


Upper ball joint to 33~63 lb ft
Lower ball joint to 55~88 lb ft
Tie rod to knuckle to 33 lb ft

[PLRX]

Tie rod housing to differential to 55 lb ft
Spring to differential carrier bolt to 37 lb ft
Support rod bracket to differential carrier bolt to 47~62 lb ft


Cam bolt to support rod to 187 lb ft
This is a VBP rod, torque to 70 lb ft
Muffler hanger bolt to 40 lb ft


Support rod to knuckle 107 lb ft
Tie rod to 37 lb ft


Shock stud to knuckle to 89 lb ft
Shock to stud 61 lb ft


Control arms to chassis to 63 lb ft
Control arms to knuckle to 140 lb ft


Upper shock bolts to 22 lb ft


Sway bar to chassis to 18 lb ft


Spindle nut to 164 lb ft


Wheel hub bolts to 66 lb ft


Torque caliper mounting bracket to knuckle to 70 lb ft

[PLRX]

First ride

Low quality short video




Last Friday I tried to install the Camber Brace following it's instructions and it is a PITA to squeeze thru the accumulator.
In the process I broke the coolant temperature sensor. I had to drain the cooling system, yes I removed the
knock sensor...the whole enchilada. I was so mad that I threw the camber brace back in the box and I was going to forget about it.

On Sunday after I came back from the Death Valley Run in my 95 LT1 and later on that evening I jumped in the
LT4 and took it for a drive. I noticed how loose the front suspension is without the Camber Brace. I cooled down and was going
to give the Camber Brace one more try BUT-THEN-I realized...The A/C system is empty

Start by disconnecting the IAT, MAF, coolant temperature sensor and Opti vent hose line. Remove the air intake ducts.

On my case I disconnected and removed the accumulator.



SCAT 9000 Series Cast Steel Crankshaft
SCAT Sportsman I-Beam Rods
SRP Forged Piston Set – Inverted Dome
JE Piston Rings
Engine was externally balanced by Dougans Racing Engines in Riverside, CA
Balanced on a Hines Microcomputer Balancer
Intake and Heads: LE2, by Elliot Portworks
The heads flow 285 cfm at .600 lift on intake
and 193 cfm at .600 lift on exhaust.

-Valves:
Duration: 223 intake 230 exhaust
Lift: .565 intake .565 exhaust
Lobe Separation Angle (LSA): 112

-Combustion Chamber: 52cc[/INDENT]


MSD Opti and coil
Magnecor Spark Plug Wires
OEM flywheel, plate and clutch
B&M Shifter
Vortex Ram Air
1000 CFM MAF
58mm TB
Hooker Shorty Headers
Magnaflow Catalysts
Magnaflow Performance Exhaust
C5 Front Brakes with drilled/slotted front and rear discs
Sway Bars: 32mm Front-26mm Rear
Tuned by PCM for Less
Compression: 11.1

No, I have not dynoed yet. But before the build up it made 306 RWHP in a Mainline Dyno.

I forgot to post the video clip

[PLRX]

YouTube - LT4 Rebuild

[Kimmer]

I am deeply impressed.

[leec4ce]

Great post, Thanks for bringit to the barn

[Corvette_Mike]

This thread should be made into the first vette barn sticky here.
I have personally seen this car, and Pete does TOP Quailty work. This car is stunning in person. When ever I see it, its mostly tail lights unless he is stopped.

Pete has made cool threads for years for all of us to enjoy. This has got to be the most information filled thread I have ever seen. Pete does a fantastic job every time documenting his work. You would be hard pressed to find someone that does this caliber of work.

Pete has another show quality vette in his garage. A 95 DRM.

I will say that I have probably learned more from Pete's threads than any other corvette member here and elsewhere.

Make this a sticky. Anyone agree?


Mike

[Iron Chef]

Originally Posted by Corvette_Mike

Make this a sticky. Anyone agree?

The 1996 C4 CE is one of my favorite Vettes EVER.

So why not!

[PLRX]

Thanks Cheff!!