I'm in the process of putting the 2.4 from "the turd" back together. Today I installed the crank pulley. Should both Z1 markings (/6 flywheel & Pulley) line up with the case centerline? When the flywheel Z1 is aligned at the case center the pulley Z1 is not. I don't see how either could be misaligned since the pulley has the pin on the back and the flywheel has the offset 6 bolt pattern. Any ideas?

Flywheel aligned on center...

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Pulley not (Z1 marks are the red arrows. Sorry about the blur.)...

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go by the pulley, remark the flywheel.

2.0-2.2 crank versus 2.4-2.7 crank


so your in the process of polishing a turd

"The Turd" is already polished. This is the backup engine.

Funny.... my mystery engine is getting the nickname "the little bastard"

Mark,
That's basically what this engine is. I've gathered parts that I didn't already have and everything is spec'd before it's assembled. New bearings, seals, rings and critical updates (oil bypass, cut cooling tins, etc.). It won't be shiney new but it will be a good solid engine.

As was mentioned earlier, the crankshafts are drilled differently on the 2.4 and 2.7 engines. Same pattern, different clocking. While you're doing the new TDC mark on the flywheel, be sure to stamp in the 30 and 35 degree marks as well, and paint mark 'em. You can see the marks through the hole above the flywheel, making is a LOT easier and safer to time the ignition at 6000 RPM.

The Cap'n

There is likely a few degrees of play in the pulley vs dowel vs crank. This error will get carried over into cam timing. Use a dial gauge on #1 piston to locate tdc, then install pulley with z1's lined up. Don't stress that dowel by turning the engine with the pulley with spark plugs in, or if you do, then first lock the flywheel and properly torque the pulley. Just my opinion.