Complete disassembly, inspection, machining, and reassembly of the 327ci V8 engine including crankshaft, pistons, camshaft, cylinder heads, and all internal components to restore engine to factory specifications.

Warnings

Tools required

Parts

• Complete gasket set (engine overhaul kit) × 1 — Fel-Pro 260-1009 or equivalent
• Piston and ring set (0.030 over standard bore) × 1 — Verify bore size after machining
• Main bearing set (standard or first undersize) × 1 — Verify crankshaft journal size
• Rod bearing set (standard or first undersize) × 1 — Verify crankshaft journal size
• Camshaft bearing set × 1 — Use OEM specification
• Timing chain and gear set × 1 — Cloyes 9-3100 or OEM equivalent
• Harmonic balancer × 1 — If worn or damaged
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal (2-piece) × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Valve stem seals (positive lock type) × 16 — Use OEM specification
• Valve springs (if worn or out of spec) × 16 — Use OEM specification
• Lifter set (hydraulic flat tappet) × 16 — Use OEM specification
• Oil pump × 1 — Melling M-55 or OEM equivalent
• Oil pump pickup tube O-ring × 1 — Use OEM specification
• Freeze plugs (expansion plugs) complete set × 1 — Use OEM specification
• Water pump × 1 — If worn or damaged
• Thermostat (180°F or 195°F) × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Spark plugs (AC R44 or equivalent) × 8 — AC R44 or equivalent heat range
• Distributor gasket × 1 — Use OEM specification
• Oil pressure sender gasket × 1 — Use OEM specification
• Fuel pump mounting gasket × 1 — Use OEM specification
• Engine assembly lube × 1 — Permatex 81950 or equivalent
• Thread sealant (non-hardening) × 1 — Permatex 59214 or equivalent
• RTV silicone (grey high-temp) × 1 — Permatex 81160 or equivalent
• Engine break-in oil additive (ZDDP) × 1 — For flat tappet camshaft

Fluids

• 5W-30 Conventional Engine Oil — 5 qt
• DEX-COOL Extended Life Coolant (Orange) — 10 qt

Preparation

1. Position engine on sturdy work surface or engine stand with adequate workspace around all sides
2. Clean exterior of engine thoroughly to prevent contamination of internal components
3. Drain all remaining coolant and oil from engine
4. Remove all external accessories: alternator, starter, water pump, fuel pump, distributor, carburetor, intake and exhaust manifolds
5. Photograph or diagram all component positions and wire routing for reference during reassembly
6. Prepare labeled containers and bags for hardware sorted by component (use plastic bags with masking tape labels)
7. Have machine shop contact information ready for cylinder boring, crankshaft grinding, valve work, and cleaning
8. Review factory service manual torque specifications before beginning reassembly phase

Procedure

1. 1

   Remove cylinder heads
   Remove valve covers. Remove rocker arm assembly by removing the 5 bolts per rocker arm shaft. Keep rocker arms, pushrods, and shafts in order for inspection. Remove the cylinder head bolts in reverse of installation pattern (start from ends, work toward center). Lift cylinder heads from block, using pry points if necessary. Do not pry between head and block surfaces.
2. 2

   Remove timing cover and components
   Remove harmonic balancer using appropriate puller (do not hammer on balancer). Remove the timing cover bolts (approximately 7 bolts securing timing cover). Remove timing cover. Mark timing chain and sprocket alignment before removal. Remove camshaft sprocket bolt. Remove timing chain, camshaft sprocket, and crankshaft sprocket as an assembly.
3. 3

   Remove camshaft
   Remove distributor drive gear from front of camshaft. Support camshaft carefully to avoid damage to lobes or bearings. Slowly and carefully pull camshaft straight out from front of block, rotating slightly to clear cam lobes past lifter bores. Use caution not to nick or gouge camshaft bearings during removal.
4. 4

   Remove lifters
   Remove all 16 hydraulic lifters from their bores. Keep lifters in order (use numbered container or lifter tray) to match with their original cam lobes and bores if reusing. Inspect each lifter base for pitting, scoring, or wear.
5. 5

   Remove oil pan and oil pump
   Remove oil pan bolts (approximately 18 bolts around perimeter) and remove oil pan. Remove oil pump mounting bolt and pull oil pump with pickup tube from main cap. Remove oil pump drive shaft from block.
6. 6

   Remove piston and rod assemblies
   Use ridge reamer to remove cylinder ridge at top of each bore before removing pistons (failure to remove ridge will break rings or damage pistons). Mark each rod cap and rod with cylinder number using number stamps on non-wear surfaces. Remove rod cap nuts and caps, keeping caps with their matching rods. Push each piston and rod assembly up and out through top of block. Install rod caps back on rods immediately to prevent mix-ups.
7. 7

   Remove crankshaft
   Mark all main bearing caps with cylinder position and direction (caps are not interchangeable). Remove main cap bolts (2 bolts per cap, 10 bolts total for 5 main caps). Remove main bearing caps carefully, noting thrust bearing location (center main on 327). Carefully lift crankshaft from block. Keep main caps in order and orientation.
8. 8

   Remove freeze plugs and cam bearings
   Drive out all freeze plugs (expansion plugs) from block using punch and hammer. The 327 has approximately 8 freeze plugs in block. If replacing cam bearings (recommended during rebuild), drive out old bearings using cam bearing removal tool or have machine shop remove them.
9. 9

   Clean and inspect block
   Hot tank or thoroughly clean block in solvent. Clean all oil passages with rifle brushes and compressed air (extremely important - any debris will damage bearings). Inspect cylinder bores for scoring, taper, and out-of-round using dial bore gauge. Measure at top, middle, and bottom in two directions. Inspect deck surface for warpage using straight edge and feeler gauges. Maximum warpage is 0.003 inch. Inspect main bearing bores for damage. Inspect threads in all bolt holes and repair with thread chaser if needed.
10. 10

    Inspect crankshaft and rods
    Clean crankshaft thoroughly including all oil passages. Measure all main journal diameters and rod journal diameters with micrometer at multiple points to check for taper and out-of-round. Standard main journal diameter is 2.4484-2.4493 inches. Standard rod journal diameter is 2.0988-2.0998 inches. Maximum taper or out-of-round is 0.0003 inch. Check for cracks using magnetic particle inspection. Inspect connecting rods for straightness, twisted condition, and proper big end bore diameter. Most rebuilds require crankshaft grinding to 0.010 or 0.020 undersize.
11. 11

    Inspect pistons and rings
    Measure piston diameter at skirt perpendicular to pin bore. Check for cracks, scoring, or damaged ring lands. Measure piston-to-bore clearance specification (should be 0.0007-0.0017 inch with new pistons). Most rebuilds require new oversize pistons. Standard bore is 4.001 inches for 327ci engine. Common overbores are 0.030, 0.040, or 0.060 inch depending on cylinder condition.
12. 12

    Inspect cylinder heads
    Clean cylinder heads thoroughly including combustion chambers and ports. Inspect head deck surface for warpage using straight edge and feeler gauges. Maximum warpage is 0.003 inch (0.006 inch can be corrected by milling). Check valve guides for wear by measuring stem-to-guide clearance. Inspect valve seats for pitting or burning. Pressure test heads for cracks (have machine shop perform). Most rebuilds require valve job including seat grinding and valve guide work.
13. 13

    Disassemble and inspect cylinder heads
    Using valve spring compressor, compress each valve spring and remove keepers. Remove retainer, spring, and valve. Keep all valves in order by cylinder and intake/exhaust position. Measure valve stem diameter and check for burning, pitting, or bending. Measure valve spring free height and pressure (should be replaced if out of spec or during complete rebuild). Check valve spring installed height. Remove and discard old valve stem seals.
14. 14

    Machine shop services
    Send block to machine shop for: hot tanking, cylinder boring to appropriate oversize (typically 0.030), deck milling if needed, cam bearing installation, main bearing bore alignment honing if needed, and final cleaning. Send crankshaft for: cleaning, magnafluxing, grinding to appropriate undersize if needed, and polishing. Send cylinder heads for: cleaning, pressure testing, valve job (seat grinding and valve grinding), valve guide work if needed, and milling if warped. Send connecting rods for: reconditioning, resizing if needed, and new rod bolts if needed.
15. 15

    Install cam bearings and freeze plugs
    If not done by machine shop, install new camshaft bearings using cam bearing installation tool. Align oil holes in bearings with oil passages in block. Drive new freeze plugs into block using appropriate size socket or freeze plug installer. Apply non-hardening sealant to outer edge of freeze plugs. Drive in until flush or slightly below surface.
16. 16

    Install crankshaft
    Clean main bearing journals and block saddles thoroughly. Install main bearing inserts in block and caps (ensure bearing tabs seat in notches). Do NOT oil bearings yet. Place Plastigage on each main journal (one at a time). Install main caps in correct position and orientation. Torque main cap bolts to proper specification per factory manual. Remove caps and measure Plastigage width to determine bearing clearance. Proper clearance is 0.0008-0.0020 inch. Remove Plastigage. Now oil bearings and journals with assembly lube. Install thrust bearing halves in center main (ensure thrust surfaces face outward). Install crankshaft. Install main caps and torque bolts to specification in three stages: snug, then 2/3 final torque, then final torque. Check crankshaft endplay with dial indicator (specification is 0.002-0.006 inch). Verify crankshaft rotates freely by hand.
17. 17

    Assemble pistons and rods
    Install new piston rings on each piston. First install oil control ring (expander and rails), then lower compression ring (dot or mark faces down), then upper compression ring (dot or mark faces up). Use ring expander tool to avoid breaking rings. Check ring end gap for each ring in its cylinder bore (should be 0.010-0.020 inch for compression rings). File rings if gap is too tight. Check ring side clearance in piston grooves. Install piston on connecting rod with proper orientation (typically valve reliefs face intake side, rod bearing tang faces outward on that bank). Install piston pin and retaining clips. Apply assembly lube to piston skirts and rings.
18. 18

    Install piston and rod assemblies
    Install rod bearing inserts in rods and caps. Oil cylinder walls with assembly lube. Stagger ring end gaps 120 degrees apart around piston. Use ring compressor to compress rings. Orient piston correctly for that cylinder (typically valve reliefs toward intake). With rod bearings oiled with assembly lube, tap piston down into bore using wooden hammer handle until rod seats on crankshaft journal. Install rod cap in correct orientation. Check rod bearing clearance using Plastigage method (proper clearance is 0.0007-0.0028 inch). After verifying clearance, torque rod cap nuts to specification per factory manual. Repeat for all 8 cylinders. Verify crankshaft still rotates freely after all rods installed.
19. 19

    Install rear main seal
    Install upper half of 2-piece rear main seal in block using seal installation tool or carefully by hand. Seal lip faces forward (toward front of engine). Apply small amount of RTV silicone to rear main cap parting line at seal area. Install lower seal half in rear main cap. Ensure seal ends are flush and do not protrude.
20. 20

    Install oil pump and pan
    Prime oil pump by filling with clean engine oil and rotating by hand. Install oil pump driveshaft in block (ensure it engages properly with distributor drive and oil pump). Install oil pump with pickup tube into main cap, ensuring pickup tube O-ring is in place. Torque oil pump bolt to specification. Clean oil pan and block mating surfaces thoroughly. Apply thin bead of RTV silicone to oil pan rail (bead thickness approximately 1/8 inch). Install oil pan and torque bolts to specification in crisscross pattern from center outward. Allow RTV to cure per manufacturer instructions before adding oil.
21. 21

    Install camshaft and timing components
    Lubricate all camshaft lobes and journals generously with assembly lube or camshaft break-in lube. Lubricate cam bearings in block. Carefully slide camshaft into block, rotating gently to avoid bearing damage. Install camshaft thrust plate if equipped. Install crankshaft sprocket on crankshaft snout. Install timing chain on camshaft sprocket. Position camshaft sprocket and chain on camshaft with timing marks aligned (camshaft sprocket mark aligned with crankshaft sprocket mark, approximately 6 o'clock on camshaft sprocket to 12 o'clock on crank sprocket). Install camshaft sprocket bolt and torque to specification. Verify timing marks remain aligned. Install distributor drive gear on camshaft. Apply thin bead of RTV silicone to timing cover. Install timing cover with new gasket. Install harmonic balancer using balancer installation tool (do not hammer on balancer).
22. 22

    Install lifters
    If reusing lifters, install each lifter in its original bore. If installing new lifters, install in any bore. Soak new hydraulic lifters in engine oil overnight before installation if possible. Coat each lifter with assembly lube before installation. Push lifters down into bores by hand.
23. 23

    Prepare and install cylinder heads
    Install new valve stem seals on valve guides (positive lock type for this era). Lubricate valve stems with assembly lube. Install valves in their original positions. Install valve springs (with dampener facing rotor on applications so equipped). Compress springs and install retainers and keepers. After all valves installed, verify keepers are properly seated by tapping valve tip with soft mallet - spring should not release. Clean head deck and block deck surfaces thoroughly. Install head gaskets on block (note any orientation markings or front indicators). Position cylinder heads on block. Install cylinder head bolts with proper length bolts in correct positions. Torque head bolts in three stages following proper torque sequence (start from center, work outward in spiral pattern). Final torque per factory manual specification.
24. 24

    Install pushrods and rocker arms
    Install pushrods in their original positions (if reusing) or any position (if new). Apply assembly lube to pushrod tips. Install rocker arm shafts and rocker arms in proper orientation. Tighten rocker arm shaft bolts gradually and evenly to prevent shaft bending. After all rocker assemblies installed, adjust valve lash if required (most 327 hydraulic lifter engines require zero lash plus 1/2 to 1 full turn preload). Adjustment procedure: rotate engine until lifter is on base circle of cam lobe (pushrod loose), then tighten rocker nut until slack is removed (zero lash), then tighten additional 1/2 to 1 turn. Repeat for all 16 valves.
25. 25

    Install external components
    Install intake manifold with new gaskets (apply RTV silicone to block end rails at intake gasket junction). Torque intake manifold bolts in proper sequence from center outward. Install exhaust manifolds with new gaskets. Install water pump with new gasket. Install fuel pump with new gasket. Install distributor (set initial timing later). Install thermostat and housing. Install temperature sensors. Install oil pressure sender. Install spark plugs (gap to 0.035 inch for points ignition). Install valve covers with new gaskets. Install all remaining accessories.
26. 26

    Pre-start preparation
    Fill crankcase with break-in oil (conventional 10W-30 or 15W-40 with ZDDP additive or dedicated break-in oil). Install new oil filter. Fill cooling system with 50/50 coolant mixture. Remove all spark plugs. Disable ignition. Crank engine with starter for 15-20 seconds to build oil pressure (observe oil pressure gauge). Stop, wait 30 seconds, repeat 2-3 times until steady oil pressure observed. Reinstall spark plugs. Connect ignition. Set initial timing to approximately 8-10 degrees BTDC for initial start.
27. 27

    Initial start and camshaft break-in
    Start engine and immediately bring RPM to 2000-2500 RPM. Maintain 2000-2500 RPM for 20-30 minutes for flat tappet camshaft break-in (critical step - do not idle, do not let RPM drop below 2000). Monitor oil pressure (should be 40-60 PSI at speed), temperature, and watch for leaks. Vary RPM slightly between 2000-2500 during break-in period. After 30 minutes, shut down and allow to cool. Check for leaks.
28. 28

    Re-torque and final adjustments
    After engine cools to warm temperature, re-torque cylinder head bolts following same sequence. Re-check valve lash adjustment on all valves. Readjust if needed. Check all external bolts and connections for proper torque. Set final ignition timing per specifications (typically 8-12 degrees BTDC for 327). Adjust carburetor idle mixture and speed.

Reassembly

1. Reinstall engine in vehicle if removed, following engine installation procedures
2. Reconnect all electrical connections, fuel lines, and cooling system hoses
3. Double-check all fasteners, connections, and fluid levels before operation
4. Perform initial test drive under light to moderate load only for first 50-100 miles
5. Change oil and filter after 500 miles of break-in period
6. Avoid full throttle or sustained high RPM operation during first 500 miles

Verification

• Engine should start readily and idle smoothly without excessive noise or vibration
• Oil pressure should be 40-60 PSI at 2000 RPM when warm, 10 PSI minimum at hot idle
• Engine temperature should stabilize at 180-195°F depending on thermostat
• No oil, coolant, or fuel leaks visible at any gasket or seal
• No excessive blow-by from PCV system or oil filler cap
• Engine should accelerate smoothly without hesitation or misfire
• Compression test should show all cylinders within 10% of each other and minimum 140 PSI
• Valve train should operate quietly without ticking or clattering (some light ticking normal for first few minutes until lifters pump up)

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