Engine Assembly Order

The following assembly for Flint and Tonawanda engine plants is general in nature as small variations were usually made from year to year.

Raw castings enter plantRaw castings received from other parts of Tonawanda engine plant
Block machining (boring/broaching) in 1 to 2 days and washedBlock machining (boring/broaching) and washed
Block begins upside down. Bore sizes on oil pan rail broadcast ahead to piston hook up area.Oil galley plugs
Galley plugsTransmission alignment pins
Main bearing caps removed, crank installed, caps reinstalled.Main bearing caps removed, crank installed, caps reinstalled.
Flywheel & pressure plate or flex plateFlywheel & pressure plate or flex plate
Cam & crankshaft gears, timing chainCam & crankshaft gears, timing chain
Piston installationPiston installation
Front engine cover and sealFront engine cover and seal
Harmonic balancerHarmonic balancer
Oil pump shaft and oil pumpOil pump shaft and oil pump
Windage tray bolts if applicableWindage tray bolts if applicable
Oil pan and hardwareOil pan and hardware
Clutch housingTDC determined, timing pointer
Engine turned uprightEngine turned upright
TDC determined, timing pointerCamshaft  lifters
Camshaft liftersBuild date/suffix code stamped *
Cylinder heads installedCylinder heads installed
Rocker arms & balls installedRocker arms & balls installed (studs already installed)
Intake manifold installed (oil filler tube if applicable, water outlet & thermostat already affixed)Valves adjusted
Valves adjustedIntake manifold installed
Valve covers installedWater outlet & thermostat installed
Miscellaneous brackets and switches installedWater pump installed
Build date/suffix code stampedSpark plugs installed
Water test with vacuum gaugeDistributor installed
Oil cavity testMiscellaneous brackets installed
Paint assemblyExhaust manifolds
Distributor installedVacuum test
Coil & plug wiresValve covers
Spark plugsPaint assembly
Temperature switchesHot test
Water and oil drainedWater and oil drained
Exhaust manifolds installedRacked & readied for shipment
Spark plug wire supports, heat shields, other miscellaneous brackets installed 
Component verification 
Racked & readied for shipment 

* Early (1965) big block engines were stamped further to the right on the engine pad due to the large plug in the end of the cylinder head after assembly at Tonawanda. This caused problems for the final assembly plants in stamping the partial VIN identification. Later the engine ID information was stamped on the left of the pad before the heads were installed allowing the right side of the engine pad to be used for the car's partial VIN to be stamped.

Two broach cutters are shown in this photograph. The cutter on the left broaches the pan rail and the upper half of the main bearing bores. The block is flipped over, registered and clamped on the pan rail, and the one on the right broaches the deck surfaces and the top horizontal surface between the decks. Each lateral row of cutting blades in each broach is set about .001" deeper than the row ahead of it. The block is clamped solid on its pallet and the overhead broach has about a six-foot stroke longitudinally across the block surface; one pass for the pan rail and one pass for the decks and top and it's done. Fresh blades in the tool left hardly any broach marks at all; as the blades wore, the broach marks became more visible.